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36047351 Spirax Sarco Design of

Steam Source Book 2012

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Acknowledgements

Improving Steam System Performance: A Sourcebook for Industry was Industry was developed under the BestPractices activity for the U. S. Department of Energy’s (DOE) Industrial Technologies Technologies Program (ITP). BestPractic undertook this project as a series of sourcebook publications. Other topics in this series include: compressed air systems, pumping systems, fan systems, process heating, and motor and drive systems For more information about DOE’s BestPractices, BestPractices, see ITP and BestPractices in the Where to Find Help section of this publication.

ITP, Lawrence Berkeley National Laboratory, and Resource Dynamics Corporation wish to thank the staff a the many organizations that so generously assisted in the collection of data for this Sourcebook. The Alliance to Save Energy, the Council of Industrial Boiler Operators, the National Insulation Association, and the North American Insulation Manufacturers Association provided valuable assistance in develop ing, compiling, and reviewing this publication.

The BestPractices Steam activity appreciates the participation of the Steam Technical Technical Subcommittee. Special thanks are extended to its co-chairs, Dr. Anthony Wright, Oak Ridge National Laboratory, and Glenn Hahn, Spirax Sarco, an Allied Partner, for providing extensive technical guidance and revie throughout the preparation of this publication. The efforts of these program and committee participants are greatly appreciated. Additionally, the contributions of the following participants are appreciated for their review of and Additionally, suggestions for this Sourcebook: Deborah Bloom, Nalco Company Sean Casten, Turbosteam Corporation Bruce Gorelick, Enercheck Systems Robert Griffin, Enbridge Gas Distribution Distribution,, Canada Dr.. Greg Harrell, Energy, Environment and Resources Center Dr Center,, University of Tennessee-Knoxville Thomas Henry, Armstrong Service Carroll Hooper, Steam Solutions, Inc. James Kumana, Kumana and Associates Andrew W. Larkin, Trigen Energy Corporation  Lloyd Mason, Condensate Return Specialists Read Free Foron 30this Days Sign up to vote title  Gil McCoy, McCoy, EERE Information Center Useful  Not useful  Cancel anytime. Kelly Paffel, Plant Support & Evaluations, Inc. Special offer forW. students: Only $4.99/month. Randall Rawson, American Boiler Manufacturers Association Douglas Riley, Millennium Chemical

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Contents Ack no wle dg em en t s Table of Contents List of Figures and Tables

Quick Start Guide Section 1: Steam System Basics Wh y St ea m ? St ea m Sy s t em Ope r a ti o n Gen er a t io n Di s tr i bu t io n E nd Us e Rec o v e r y

Section 2: Performa Performance nce Improvement Opportunities Ov er v i ew Sy s te ms Appr o a c h Common Performance Impro vement Opportunities BestPractices Steam System Performance Tools Steam System Training Ov er v i ew of Fi na nc in g St e a m Sy s t e m I m pr o v eme nt s Master your semester with Scribd Read Free Foron 30this Days Sign up to vote title & The NewSection York3:Times  Useful  Not useful Where to Find Help Cancel anytime.

Special offer for students: Only $4.99/month. The Industrial Technologies Program and BestPractices

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List of Figures F ig ur e 1 .

St e a m Sy s t e m Sc he ma t ic

F ig ur e 2 .

Firetube Boiler Fi

Figu Fi gure re 3.

Wat ater ertu tube be Bo Boil iler er

Figure Figu re 4.

Thermostati Therm ostatic c Steam Trap with a Bell Bellows ows Elem Element ent

Figure Figu re 5.

Thermostati Therm ostatic c Steam Trap with a Bime Bimetalli tallic c Elem Element ent

F ig ur e 6 .

Inverted Bucket Steam Trap

F ig ur e 7 .

Float and Thermostatic Steam Trap

F ig ur e 8 .

Thermodynamic Disc Steam Trap

F ig ur e 9 .

Shell and Tube Heat Exchanger

Figure Figu re 10. Comp Component onentss of a Plate and Fram Frame e Heat Exch Exchange angerr Figure Figu re 11. Confi Configurat guration ion of a Jack Jacketed eted Kett Kettle le Heat Excha Exchanger nger F ig ur e 1 2 . T h er mo c o mpr e s s o r Ope r a t io n Figure Figu re 13. Conde Condensate nsate Rece Receiver iver Tank and Pump Combi Combinatio nation n Figure 14. Flash Steam Reco ver y Vessel

List of Tables Table 1. Key IOF Steam End-Use Equipment Table 2. Common Performance Performance Improvement Opportunities Opportunities for the Generation, Distribution, and Recover y Parts of Industrial Steam Systems



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Quick S

Quick Start Guide This Sourcebook is designed to provide steam system users with a reference that describes the basic steam system components, outlines opportunities for energy and performance improvements, and discusses the benefits of a systems approach in identifying and implementing these improvement opportunities. The Sourcebook is divided into three main sections as outlined below. This Sourcebook is not intended to be a comprehensive technical guide on improving steam systems, but rather a document that makes users aware of potential performance improvements, provides some practical guidelines, and directs the user to helpful resources. A systems approach analyzes the supply and the demand sides of the system and how they interact, essentially shifting the focus from individual components to total system performance. The cost-effective operation and maintenance of a steam system require attention not only to the needs of individual pieces of equipment, but also to the system as a whole. Often, operators are so focused on the immediate demands of the equipment, they overlook the broader question of how system parameters affect the equipment.

Section 1: Steam System Basics Scribd Master your semester with For users unfamiliar with the basics of steam systems, or for users seeking a refresher, a brief & The New York Times discussion of the terms, relationships, and N

Special offer for students: Only $4.99/month. important system design considerations is provided. Users already familiar with industrial

Section 2: Performance Improvemen Opportunities This section discusses important factor should be considered when industrial f seek to improve steam system perform to lower operating costs. This section al an overview of the financial considerat ed to steam system improvements. Add this section discusses several resources developed through the U. S. Departme Energy’s (DOE) BestPractices Steam activ identify and assess steam system improv opportunities. N

Section 3: Where to Find Help This section provides a directory of ass and other organizations involved in th system marketplace. This section also a description of the BestPractice BestPracticess Steam a directory of contacts, and a listing of resources and tools, such as publication training courses, and videos. N

Appendices The Sourcebook includes three appen Appendix A is a glossary defining term steam systems. Appendix B contains a steam system tip sheets. Developed thr  DOE’s DOE’ s BestPractices Steam activities, Read Free Foron 30this Days Sign up to vote title  sheets discuss common opportunities t Not useful  Useful  industrial facilities can use to improve Cancel anytime. ance and reduce fuel use. Appendix C p guidelines for submitting suggested ch N

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Steam Syst

Section 1: Steam System Basics Why Steam? There are three principal forms of energy used in industrial processes: electricity electricity,, direct-fire direct-fired d heat, and steam. Electricity is used in many different ways, including mechanical drive, heating, and electrochemical reactions. Direct-fired energy directly transfers the heat of fuel combustion to a process. Steam provides process heating, pressure control, mechanical drive, and component separation, and, is a source of water for many process reactions. Steam has many performance advantages advantages that make it an indispensable means of delivering energy. These advantages include low toxicity, ease of transportability, high efficiency, high heat capacity, and low cost with respect to the other alternatives. Steam holds a significant amount of energy on a unit mass basis (between 1,000 and 1,250 British thermal units per pound [Btu/lb]) that can be extracted as mechanical work through a turbine or as heat for process use. Since most of the heat content of steam is stored as latent heat, large quantities of heat can be transferred efficiently at a constant temperature, which is a useful attribute in many process heating applications.

Master your Scribd Steam is semester also used in manywith direct contact applications. For example, steam is used as a source of & The New York Times hydrogen in steam methane reforming, which is important process for many chemical and Special offer foran students: Only $4.99/month. petroleum refining applications. applications. Steam is also

The many advantages that are availab steam are reflected in the significant am of energy that industry uses to generat example, in 1994, industry used about trillion Btu of steam energy, which rep about 34% of the total energy used in i applications for product output.1

Steam use in the Industries of the Futu especially significant. For example, in 1 the pulp and paper industry used appro 2,197 trillion Btu of energy to generate accounting for about 83% of the total e used by this industry industry.. The chemicals used approximately 1,855 trillion Btu o to generate steam, which represents ab 57% of the total energy used in this in The petroleum refining industry used 1,373 trillion Btu of energy to generate which accounts for about 42% of this i total energy use.3

Steam System Operation This Sourcebook uses four categories to steam system components and ways to steam system performance: generation tion, end use, and recovery. recovery. These four follow the path of steam as it leaves th return andRead returns the condensate Free For 30this Days Sign up tovia vote on title N

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Steam is generated in a boiler or a heat steam generator by transferring the hea

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Steam System Basics N

Distribution The distribution system carries steam from the boiler or generator to the points of end use. Many distribution systems have several take-off lines that operate at different pressures. These distribution lines are separated by various types of isolation valves, pressure-regulating valves, and, sometimes, backpressure turbines. A properly performing distribution system delivers sufficient quantities of high quality steam at the right pressures and temperatures to the end uses. Effective distribution system performance requires proper steam pressure balance, good condensate drainage, adequate insulation, and effective pressure regulation. End Use There are many different end uses of steam. Examples of steam’s diverse uses include process heating, mechanical drive, moderation of chemical reactions, and fractionation of hydrocarbon components. Common steam system end-use equipment includes heat exchangers, turbines, fractionating towers, strippers, and chemical reaction vessels. N

In a heat exchanger, the steam transfers its latent heat to a process fluid. The steam is held in the heat exchanger by a steam trap until it condenses,

at which point the trap passes the condensat into the condensate return system. In a turb the steam transforms its energy to mechanic work to drive rotating machinery such as pu compressors, or electric generators. In fractio ing towers, steam facilitates the separation o various components of a process fluid. In str ping applications, the steam pulls contamin out of a process fluid. Steam is also used as a source of water for certain chemical reaction steam methane reforming, steam is a source hydrogen. N

Recovery The condensate return system sends the con sate back to the boiler. The condensate is retu to a collection tank. Sometimes the makeup water and chemicals are added here while times this is done in the deaerator. From the lection tank the condensate is pumped to th deaerator, which strips oxygen and non-cond able gases. The boiler feed pumps increase th feedwater pressure to above boiler pressure a inject it into the boiler to complete the cycle

Figure 1 provides a general schematic descrip of the four principal areas of a steam system. following sections discuss the components in these areas in greater detail.

Pressure Reducing Valve

Distribution Combustion Gases

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Isolation Valve

Forced Draft Fan

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Steam Syste

Generation The generation part of a steam system uses a boiler to add energy to a feedwater supply to generate steam. The energy is released from the combustion of fossil fuels or from process waste heat. The boiler provides a heat transfer surface (generally a set of tubes) between the combustion products and the water. The most important parts of the generating system include the boiler, the fuel supply, combustion air system, feedwater system, and exhaust gases venting system. These systems are related, since problems or changes in one generally affect the performance of the others. N

Boilers There are two basic types of boilers: firetube and watertube. The fundamental difference between these boiler types is which side of the boiler tubes contains the combustion gases or the boiler water/steam.


Firetube boilers. In firetube boilers, the c

tion gases pass inside boiler tubes, and transferred to water on the shell side. A tative firetube boiler is shown in Figure marine boilers are the most common t industrial firetube boiler. The Scotch m boiler is an industry workhorse due to cost, and advantages in efficiency and Scotch marine boilers are typically cyli shells with horizontal tubes configured the exhaust gases pass through these tu ferring energy to boiler water on the sh

Scotch marine boilers contain relativel amounts of water, which enables them respond to load changes with relatively change in pressure. However, since the typically holds a large water mass, it re more time to initiate steaming and mo to accommodate changes in steam pres Also, Scotch marine boilers generate ste


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Steam System Basics the shell side, which has a large surface area, limiting the amount of pressure they can generate. In general, Scotch marine boilers are not used where pressures above 300 psig are required. Today, the biggest firetube boilers are over 1,500 boiler horsepower (about 50,000 lbs/hr).5 Firetube boilers are often characterized by their number of passes, referring to the number of times the combustion (or flue) gases flow the length of the pressure vessel as they transfer heat to the water. Each pass sends the flue gases through the tubes in the opposite direction. To make another pass, the gases turn 180 degrees and pass back through the shell. The turnaround zones can be either dryback or water-back. In dryback designs, the turnaround area is refractorylined. In water-back designs, this turnaround zone is water-cooled, eliminating the need for the refractory lining.


Watertube boilers. In watertube boilers, boiler

water passes through the tubes while the exh gases remain in the shell side, passing over t tube surfaces. A representative watertube boi shown in Figure 3. Since tubes can typically withstand higher internal pressure than the chamber shell in a firetube, watertube boiler used where high steam pressures (3,000 poun per square inch [psi], sometimes higher) are required. Watertube Watertube boilers are also capable o high efficiencies and can generate saturated superheated steam. In fact, the ability of wat tube boilers to generate superheated steam m these boilers particularly attractive in applica tions that require dry, high-pressure, high-en steam, including steam turbine power generat

The performance characteristics of watertube boilers make them highly favorable in proce industries, including chemical manufacturin


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Steam Syste pulp and paper manufacturing, and refining. Although firetube boilers account for the majority of boiler sales in terms of units, water-tube boilers account for the majority of boiler capacity.7 Waste Heat Recovery Boiler (WHRB). These boilers

may be either firetube or watertube design and use heat that would otherwise be discarded to generate steam. Typical sources of heat for WHRBs include exhaust gases or high temperature products from an external manufacturing manufacturing process in refineries and chemical manufacturing facilities, or combustion of a waste fuel in the boiler furnace. Heat Recovery Steam Generators (HRSGs). HRSGs

transfer energy from the exhaust of a gas turbine to an unfired or supplementary fired heat-recovery steam generator to produce steam. Exhaust gases leave the gas turbine at temperatures of 1000°F (538°C) or higher and can represent more than 75% of the total fuel energy input. This energy can be recovered by passing the gases through a heat exchanger (steam generator) to produce hot water or steam for process needs. If the amount of steam needed by the process exceeds the amount produced by simple heat recovery,, then supplementary fuel can be burned recovery in the ducting between the gas turbine and the HRSG.

water heat exchangers. Since these eco are not designed to handle flue gas cond noncondensing economizers economizers must be o temperatures that are reasonably above points of the flue gas components. The point of the flue gases depends largely amount of water in the gas, which, in t related to the amount of hydrogen in t For example, to avoid condensation in exhaust gases produced by burning nat the exhaust gas temperature should typ kept above 250°F. Condensing econom designed to allow condensation of the gas components. Due to latent heat rec these economizers typically extract mo than do noncondensing economizers. special materials are required.

For more information on economizers, Steam Tip Sheet Number 3 titled Use Fe Economizers for Waste Heat Recovery in Recovery in Ap

Combustion air preheaters. Combustion a

heaters are similar to economizers in transfer energy from the flue gases bac system. In these devices, however, however, the transferred to the incoming combustio efficiency benefit is roughly 1% for eve increase in the combustion air temperat

Boiler Insulation The walls and combustion regions of b typically lined with insulating material reduce energy loss and to prevent leaka are several types of boiler insulating m including brick, refractory, insulation an  insu TheRead selection andon design of boiler Free For 30 Days Sign up to vote this title materials depends largely on theage an  Not useful of  theUseful boiler. CancelSince anytime.the insulating linin exposed to high temperatures and is su degradation, it should be periodically i N

Superheaters. Superheaters add energy to steam,

resulting in a steam temperature that exceeds the saturation temperature at a specific pressure. Superheaters can be convective or radiant. Radiative superheaters rely on the energy transferred directly from the combustion flame to increase the energy level of the steam, while convective superheaters rely on the transfer of additional Special offer forenergy students: Onlythe $4.99/month. from flue gases to the steam.


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Steam System Basics Combustion control system. The combustion control

Safety valve. The safety valve is the most impor

system regulates the fuel air mixture to achieve safe and efficient combustion and maintains steam system pressure. Control systems have varying levels of sophistication. Simple systems use a fixed linkage between the fuel-regulating valve and the combustion air damper. This is called single point positioning. A change in steam pressure makes a proportional change in the combustion air and fuel. Advanced systems rely on signals from transmitters to determine independent fuel valve and air damper positions. This is called a full monitoring system.

valve on the boiler and keeps the boiler from exceeding its maximum allowable working pressure (MAWP).

For more information, see the Steam Tip Sheet Number 4 titled Improve titled Improve Your Boiler’s Combustion Efficiency in Efficiency in Appendix B. Burner flame safeguard system. A flame safeguard

system is an arrangement of flame detection systems, interlocks, and relays which will sense the presence of a proper flame in a furnace and cause fuel to be shut off if a hazardous condition develops. Modern combustion systems are closely interlocked with flame safeguard systems and also pressure-limit switches, low-water level cutoffs, and other safety controls that will stop the energy input to a boiler when an unsafe condition develops. The flame safeguard system senses the presence of a good flame or proper combustion and programs the operation of a burner system so that motors, blowers, ignition, and fuel valves are energized only when they are needed and then in proper sequence. Safety shutoff valve. Safety shutoff valves isolate the Master your semester with Scribd fuel supply to the boiler in response to certain conditions such as low or high gas pressure or & The New Times satisfied loadYork demand. The type of safety shutoff

valves and the Only settings are often determined by Special offer for students: $4.99/month. code or insurance requirements.

Steam pressure control. Steam pressure contro

regulate the combustion equipment to main a constant pressure in the steam header. As t pressure rises above or falls below the pressu setting, the control adjusts the burner firing to bring the pressure back to the setpoint.

Nonreturn valve. The nonreturn valve is a com

nation shutoff and check valve that allows st out of the boiler, but prevents backflow from steam header in the event the boiler pressure drops below that of the header. The valve is opened only when the pressure inside the bo rises slightly above the steam header pressur

Steam flow meter. Steam flow meters are helpf

in evaluating the performance of the system and can provide useful data in assessing boil performance,, calculating boiler efficiency performance efficiency,, tracking the amount of steam required by system. In some systems, steam flow meters provide a measurement signal for the boiler control system. Additionally, steam flow met can be useful in benchmarking efforts.

There are three basic types of steam flowmet differentiall pressure (DP), vortex, and Coriol differentia Differential Different ial pressure flowmeters rely on the change in pressure as steam flows by an elem such as a nozzle, orifice, or venturi. This pres difference provides an indication of flow velo  which, inRead turn, can be on used to determine the Free For 30this Days Sign up to vote title  prin flow rate. Vortex flowmeters rely on the Useful past  Not useful that flow an element Cancel anytime. creates vortices th have frequencies that correspond to the flow velocity.. Coriolis flowmeters rely on tubes pl velocity

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Steam Syste Feedwater flow control valve. A modulating feed-

water flow control valve moves up or down in response to the water level transmitter transmitter(s). (s). On smaller firetube boilers, it is not uncommon for the feedwater valve to operate in a closed or open position, depending on the water level transmitter signal. Softener. Softeners remove hardness minerals,

such as calcium, magnesium, and iron, from a water supply. The presence of hardness in boiler water leads to many problems, including scale buildup and foaming, which reduce boiler efficiency and can cause tube failure. Softeners reduce this problem through an ion exchange process. As the hard water passes through a chamber filled with resin, an exchange occurs that removes hardness minerals from the water. The sodium that replaces the hardness minerals has a higher solubility in water and generally will not form scale.

oxygen removal as deaerators and deaer heaters, typically providing water with o levels of 0.5 to 1 parts per million (ppm

In applications that require lower oxyg than achievable with a deaerator, deaer heater, or open feedwater heater, a che agent, known as an oxygen scavenger used to remove more oxygen. In most an oxygen scavenger is part of the syst treatment program.

For more information on these devices Deae Steam Tip Sheet Number 18 titled titled Deae Industrial Steam Systems, Systems , provided in Ap

Feedwater pump. Feedwater pumps trans

from the deaerator to the boiler. Feedw pumps are driven by electric motors or turbines. In a modulating feedwater sy feedwater pumps run constantly as opp an on/off operation in relatively small

Pretreatment equipment. Pretreatment equipment

improves the quality of the incoming water so that it may be used in the boiler without excessive scaling or foaming, which can reduce boiler efficiency and cause tube failure. Pretreatmen Pretreatmentt equipment includes, but is not limited to, clarifiers, filters, softeners, dealkalizers, decarbonators, reverse osmosis (RO) units, and demineralizers. Deaerator, deaerating heater Deaerator, heater,, and atmospheric atmospheric deaerator. The presence of oxygen in the boiler system

can be a significant problem due to its corrosivity at high temperatures. Deaerators Deaerators and deaerating heaters use heat, typically steam, to reduce the oxygen content in water. Deaerators and deaerating heaters are typically pressurized tanks that raise the water temperature to the point of satuSpecial offer forration. students: Onlyalso $4.99/month. They break the incoming water into either fine droplets or thin sheets to facilitate the


Collecting/Storage Collecting/S torage tank. The return of co

is often erratic due to changing steam r ments by the end uses. The condensate is usually returned to a condensate recei directly to the deaerator if the system do have a receiver. Pretreated water may als in a tank prior to use. This provides the system with additional water capacity i the pretreatment equipment malfuncti condensate and pretreated water, or ma are transferred from the storage tanks t deaerator prior to being sent to the boi N

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Boiler Combustion Air System Read Free Foron 30this Days Sign up to vote title

 th The combustion air system supplies Useful Not useful   necessaryCancel for the combustion reaction. anytime. vide enough air for the amount of fuel industrial boilers, fans are typically req

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Steam System Basics Induced draft fan. Induced draft fans are located

on the outlet gas side of the boiler and pull flue gases out. The induced draft fan creates a slightly negative furnace pressure that is controlled by outlet dampers on the boiler. In some systems where a bag house, mechanical collector, collector, or precipitator is involved, special considerations should be given in sizing and selection of this fan. Damper. Dampers control the amount of air

allowed into and out of a combustion chamber. Dampers, in combination with fuel regulating devices, are positioned by the combustion control system to achieve certain fuel-to-air ratios. Dampers on the boiler outlet are used to regulate the negative furnace draft.

Boiler Fuel System There are many different types of fuels used in boilers, requiring several different types of fuel handling systems. Fossil fuels such as coal, oil, and gas are most commonly used. Waste fuels are used in many industries, particularly the forest products, petroleum refining, and chemical manufacturing industries where there is an available supply of waste products such as bark, wood chips, black liquor, and refinery gas. N

For more information, see the Steam Tip She Number 15 titled Benchmark titled Benchmark the Fuel Cost of Steam Generation in Appendix B.

Burner. Burners combine the fuel and air to init

combustion. There are many different types burners due to the many different types of fu Additionally, burners have different perform characteristics characterist ics and control requirements. Som burners are on/off while others allow precise setting of the fuel:air mixture over a range o conditions. Some burners can fire different ty of fuel, allowing boiler operation to continu despite the loss of one fuel supply.

Boiler Blowdown System The boiler blowdown system includes the and the controls for the continuous blowdow and bottom blowdown services. Continuous blowdown removes a specific amount of boi water (often measured in terms of percentag feedwater flow) in order to maintain a desire level of total dissolved solids in the boiler. Se ting the flow for the continuous blowdown i typically done in conjunction with the wate treatment program. Some continuous blowd systems rely on the input of sensors that det the level of dissolved solids in the boiler wat N

Fuel regulating valve. In gaseous and liquid fuels,

regulating valves control the fuel delivered to the boiler.. In many systems, these valves can be boiler quickly shut in response to an operating problem. Fuel. The fuel types that are commonly used in

boilers include natural gas, coal, propane, fuel oils, and waste fuels (for example, black liquor, bark, and refinery gas). Fuel type significantly affects boiler operation, including efficiency, efficiency, emissions, and operating cost. Natural gas Special offer for students: Only 36% $4.99/month. accounts for about of the total U.S. industry boiler capacity. Coal accounts for about 14% of


The bottom blowdown is performed to remo particulates and sludge from the bottom of boiler. Bottom blowdowns are periodic and a typically performed a certain number of time per shift or according to a set schedule. In so systems, bottom blowdowns are controlled b an automatic timer. Bottom blowdown shou  never be Read permitted unless it is recommended Free For 30this Days Sign up to vote on title  by the boiler manufacturer. This is because in Useful Not useful   higher pressureCancel boilers, especially those abov anytime. 700 pounds per square inch gauge (psig), bot blowdown may cause water starvation in som

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Steam Syste than would be required without the flash tank. Blowdown heat exchangers are most often used to preheat boiler makeup water. For more information on boiler blowdowns, see the Steam Tip Sheets Numbers 9 and 10 titled and Recover Heat from Minimize Boiler Blowdown, Blowdown , and Recover Boiler Blowdown in Appendix B.

Distribution The distribution system transports steam from the boiler to the various end uses. Although distribution systems may appear to be passive, in reality, these systems regulate the delivery of steam and respond to changing temperature and pressure requirements. Consequently Consequently,, proper performance of the distribution system requires careful design practices and effective maintenance. The piping should be properly sized, supported, insulated, and configured with adequate flexibility. Pressure-regulating Pressure-regulat ing devices such as pressurereducing valves and backpressure turbines should be configured to provide proper steam balance among the different steam headers. Additionally, the distribution system should be configured to allow adequate condensate drainage, which requires adequate drip leg capacity and proper steam trap selection. Steam distribution systems can be broken down into three different categories: buried pipe, above-ground, and building sections, and selection of distribution components (piping, insulation, etc.) can vary depending on the category.

Pipingsemester with Scribd Master your Steam piping transports steam from the boiler to the end-use services. Important characteristics of & The New York Times N

steam system piping are that it is Special offer forwell-designed students: Only $4.99/month. adequately sized, configured, and supported. Installation of larger pipe diameters may be

number of appropriately sized drip legs t effective condensate drainage. Addition piping should be pitched properly to p the drainage of condensate to these dri Typically, these drainage points experie very different operating conditions, no operation and start-up; both load cond should be considered in the initial desi

Insulation Thermal insulation provides important energy savings, and performance benef terms of safety, insulation reduces the surface temperature of the steam pipin lessens the risk of burns. A well-insulat also reduces heat loss to ambient work which can make the work environmen comfortable. Consequently, the energy benefits include reduced energy losses the steam system and reduced burden cooling systems that remove heat from w In addition to its safety and energy ben insulation increases the amount of stea available for end uses by decreasing th of heat lost from the distribution syste N

Important insulation properties includ conductivity, strength, abrasion resista ability, and resistance to water absorptio conductivity is the measure of heat tra unit thickness. Thermal conductivity of varies with temperature; consequently, important to know the right temperatu when selecting insulation. Strength is t ure of the insulation’ insulation’ss ability to mainta integrity under mechanical loads. Abra shearin ance is the tothis withstand Read Free Foron 30 Days Sign up toability vote title  Workability is a measure of the ease wi Useful  Not useful  the insulation is installed. Water absorp Cancel anytime. refers to the tendency of the insulation moisture. Insulation blankets (fiberglas

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Steam System Basics program titled 3E Plus that allows users to determine the energy losses associated with various types and thicknesses of insulation. The 3E Plus program facilitates the assessment of various insulation systems to determine the most cost-effective solution for a given installation. See Section 2, page 27 for more about 3E Plus Insulation software, which can help steam users assess insulation opportunities. For more information on insulation, refer to Steam Tip Sheets Numbers 2 and 17 titled Insulate titled Insulate Steam and Install Distribution and Condensate Return Lines and Install Removable Insulation on Uninsulated Valves and Fittings. Both can be found in Appendix B.

Valves In steam systems, the principal functions of valves are to isolate equipment or system branches, to regulate steam flow, and to prevent overpressurization. The principal types of valves used in steam systems include gate, globe, swing check, pressure reducing, and pressure relief valves. Gate, globe, and swing check valves typically isolate steam from a system branch or a component. Pressure reducing valves (PRV) typically maintain certain downstream steam pressure conditions by controlling the amount of steam that is passed. These reducing valves are often controlled by transmitters that monitor downstream conditions. Pressure relief valves release steam to prevent overpressurization of a system header or equipment. N

trap as an integral part of the unit. Additiona accessories include water gauge connections, thermometerr connections, and vent connect thermomete

Steam separators can be installed in either a ho zontal or vertical line. They are capable of re ing 99% of particulate entrainment 10 micro and larger over a wide range of flows. Separa are often designed in accordance with ASME Code, Section VIII, Division 1 with pressures 300 psig.

Steam Accumulators A steam accumulator is a large insulated pres vessel, partially filled with hot water (saturat liquid). When steam supply exceeds demand excess high-pressure steam is charged into th accumulator through special charging nozzle The steam is condensed, giving up its latent heat, to raise the pressure, temperature, and content of the water body. When the steam demand exceeds the supply, the pressure in t accumulator drops and the additional requir steam flashes from the water, taking back the h previously stored. A simple system of contro valves and check valves regulates the chargin and discharging. The excess steam is charged quietly and smoothly, and when steam is need it is available with the speed of a control val operation. There is also an accumulator desig that stores hot water for use as boiler feedwa N

Steam Traps Steam traps are essential for proper distributi system performance. During system start-up traps allow air and large quantities of conden  to escape. During operation, the trap Read Free Foron 30this Days Sign up to system vote title  the allow collected condensate to pass into Useful  Not useful  condensate return Cancelsystem, anytime. while minimizing accompanying loss of steam. There are three primary types of traps: thermostatic, mechani N

Steam Separators In some steam systems, wet steam is generated. This wet steam contains water droplets that can reduce the effectiveness of the steam system. Water droplets erode turbine blades and passages, and pressure reducing valves, thus reducing effiSpecial offer for students: $4.99/month. ciency and life.Only Furthermore, Furthermore , liquid water can significantly reduce heat transfer rates in heat N


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Steam Syste Bellows traps. Bellows traps include a valve

element that expands and contracts in response to temperature changes. Often a volatile chemical such as alcohol or water is inside the element. Evaporation provides the necessary force to change the position of the valve. At start-up, the bellows trap is open due to the relative cold condition. This operating condition allows air to escape and provides maximum condensate removal when the load is the highest. Bellows traps can fail either open or closed. The configuration of a bellows steam trap is shown in Figure 4.

Steam and/or Hot Condensate Depending on Trap

Bellows Element Valve Liquid Condensate & Flash Out

Steam & Condensate In Seat

Figure 4. Thermostatic Steam Trap with a Bellows Element

Hot or Subcooled Liquid Condensate

Bimetal

Steam & Condensate In Valve

Seat

Figure 5. Thermostatic Steam Trap with a B Element

outlet opening in the trap body. When densate is present, the ball covers the o opening, thereby keeping air and steam escaping. As condensate accumulates in trap, the ball floats and uncovers the o opening. This movement allows the to flow continuously from the trap. Un are equipped with a separate air vent, b traps cannot vent air on start-up.

Float and lever traps. Float and lever trap Bimetallic traps. Bimetallic traps rely on the bend-

ing of a composite strip of two dissimilar metals to open and close a valve. Air and condensate pass freely through the valve until the temperature of the bimetallic strip approaches the steam temperature. After steam or relatively hot condensate heats the bimetallic strip and causes it to close the valve, the trap remains shut until the temperature of the condensate cools sufficiently to allow the bimetallic strip to return to its original shape and thereby open the valve. Bimetallic traps can fail in either the open or closed posiSpecial offer fortion. students: $4.99/month. The Only configuration of a bimetallic steam trap is shown in Figure 5.


lar in operation to ball float traps excep is connected to a lever. When the ball upward due to accumulation of condens the trap body, the attached lever moves a valve to open. This action allows cond continuously flow from the trap. If the c load decreases and steam reaches the tra ward ball movement causes the valve to thereby keeping steam from escaping. U are equipped with a separate air vent, flo lever traps can not vent air on  start-up. S Read Free For 30 Days Sign up to vote on this title cussion on float and thermostatictraps.  Useful  Not useful Cancel anytime.

Inverted bucket traps. Inverted bucket tr

somewhat more complicated than floa

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Steam System Basics depleted of their condensate seal when applied in superheated steam service. If this occurs, the trap will continuously discharge live steam. This trap type is not recommended for superheated steam service, unless special installation conditions are met. The configuration of an inverted bucket steam trap is shown in Figure 6. Seat Liquid Condensate & Flash Out

Steam & Condensate In

Air Vent

Steam Space Condensate Level Valve

Steam Spaces

Float

Lever

Condensate Level Steam Bubbles Vent Hole Valve

Seat

Liquid Condens & Flash Out

Figure 7. Float and Thermostatic Steam Trap

Inverted Bucket

Lever

Disc traps. Disc traps use the position of a flat Steam & Condensate In

Figure 6. Inverted Bucket Steam Trap Trap

Open bucket traps. Open bucket traps consist of an

upright bucket that is attached to a valve. At start-up, the bucket rests on the bottom of the trap body. In this position, the valve is wide open. As condensate accumulates in the trap body on the outside of the bucket, the bucket floats upward, causing the valve to close. When sufficient condensate accumulates outside the bucket, it spills over the top and fills the inside of the bucket. At this time, the bucket sinks, causing the valve to open. This trap is also prone to failure when applied in superheated steam service because of the loss of the condensate seal. Like inverted bucket traps, open bucket traps have intermittent discharge.

Master your semester with Scribd & The New York Times Float and Thermostatic (F&T) traps. Float and therSpecial offer for students: mostatic (F&T) Only traps$4.99/month. are similar to float and lever traps except they include a thermostatic element

to control steam and condensate flow. When condensate flows through the trap, the disc raised, thereby causing the trap to open. As steam and air pass through the trap, the disc moves downward. The force that causes the d to move downward is generated generated by the the differ in pressure between the low-velocity steam a the disc and the high-velocity steam that flo through the narrow gap beneath the disc. traps commonly have an intermittent discha and, when they fail, they normally fail open The configuration of a disc steam trap is sho in Figure 8. Generally, the air removal capab of this trap type is poor unless equipped wi additional components (like the float and thermostatic trap).

Outlet Port Seating Surface

Inlet Port


 Steam & Condensate In


Useful

Flash Vapor Clos Valve Disc

 Chambe Bonnet Valve Disc

Liquid Conden

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Lever traps. Lever traps are a variation of the

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thermodynamic piston trap. They operate on the same principal as a piston trap but with a lever action to pass large amounts of condensate and air on a continuous basis. Their primary failure mode is open.

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Steam Syste

Orifice traps. Orifice traps are of two basic types:

orifice plate and short tube. Both trap types operate under the exact same principles. A simple orifice plate steam trap consists of a thin metal plate with a small-diameter hole (orifice) drilled through the plate. When installed, condensate that accumulates is continuously removed as the steam pressure forces the condensate through the orifice. During conditions conditions when no no condensate is present, a limited amount of steam flows through the orifice. The report Review report Review of Orifice Plate Steam Traps on page 49 of the Where to Find Help section provides information for making informed decisions about when orifice plate steam traps should be considered for use in new or existing steam systems. Additional information regarding steam traps is available in the Steam Tip Sheet Number 1 titled Inspect and Repair Steam Traps, Traps, found in Appendix B.

Steam Meters The use of flowmeters within the distribution system can provide important data for monitoring the efficiency of a process or an end use. Tracking the amount of steam required can be particularly useful in benchmarking efforts. The types of steam flowmeters are discussed in the Generation Section. N

Master your semester with Scribd & The New York Times End Use

Special offer for students: Only $4.99/month. Steam system end-use equipment transfers steam energy into other forms of useful energy. Common

in the Introduction. Some of the major components are discussed in this sectio

For the purposes of this discussion, stea equipment is grouped into three basic c I

Industries of the Future11 (IOF) key equipment

I

Conditioning and control equipmen

I

Additional equipment.

The key IOF equipment category inclu largest uses of steam in those industries IOF facilities use steam for other servic the key end uses account for the larges of steam use. The conditioning equip category includes equipment that facili effective use of steam. The additional e category includes equipment that is use industries indust ries and, though significant, significant, doe account for most of the steam use in IOF

Industries of the Future Key End-Use Equ In the three IOF industries of forest pro petroleum refining, and chemicals, steam for the largest amount of end-use energ another IOF industry, steel production, represents a significant amount of end-u and is used to generate most of that in on-site electric power. Table 1 provides key steam-supplied end-use equipment industries.

Condensers In steam applications, condensers are a with condensing steam turbines and w  pleRead stage ejector Free Forsystems. 30this Days Sign up to vote on titleIn steam turb  cations, condensers typically operate u Useful  Not useful  vacuum. Cancel Theyanytime. remove energy from the steam, allowing it to be recovered as co In steam ejector applications, condenser N

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Table 1. Key IOF Steam End-Use Equipment

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Equipment Condenser

Process Application Steam turbine operation

Distillation tower

Distillation, fr f ractionation

Industry Aluminum, Ch Chemical Manufacturing, Fo Forest Products, Produ cts, Glass Glass,, Metal Casti Casting, ng, Petr Petroleum oleum Refining, Refin ing, and Steel Steel Chemical Manufacturing, Pe P etroleum Refining

Dr yer

Drying

Forest Products

Evaporator

Evaporation/concentration

Chemical Ma Manufacturing, Fo Forest Pr Products Petroleum Refining

Process he heat at exchanger

Alkylation, Process air heating,Pr g,Proocess wat ateer heating, Gas re r ecovery/Light en e nds d is istillation, Isomerization, Storage ta tank he heating Visbreaking/Coking

Aluminum um,, Chemical Manufacturing, Forest Products, Glass, Metal Ca C asting, Petroleum Refining, and St Steel

Reboiler

Fractionation

Petroleum Refining

Reformer

Hydrogen generation

Chemical Manufacturing, Pe Petroleum Refining

Separator

Component separation

Chemical Manufacturing, Fo Forest Products, Petroleum Refining

Steam ejector

Condenser operation, Vacuum distillation

Aluminum, Chemical Manufacturing, Forest Products, Produ cts, Glass Glass,, Metal Casti Casting, ng, Petr Petroleum oleum Refining, Refin ing, and Steel Steel

Steam injector

Agitation/blending, He H eating

Chemical Manufacturing, Fo F orest Products, Petroleum Refining

Steam tu turbine

Power ge generation, Compressor me mechanical driv dr ive, e, Hy Hydr droocr crac ackkin ing, g, Na Naph phth thaa re refo form rmin ing, g, Pump mechanical drive, Feed pump mechanical drive

Aluminum, Chemical Ma Manufacturing, Forest Prod Pr oduc ucts ts,, Gl Glaass ss,, Me Meta tall Cas asti ting ng,, Pet etro role leum um Refining, and Steel

Stripper

Distillation (crude and vacuum units), Catalytic cracking, cracking, Asphalt processing, processing, Catalytic reforming, reforming, Component removal, Component separation, Fractionation, Hydrogen treatment, Lube oil processing

Chemical Manufacturing, Petroleum Refining

Thermocompressor

Drying, Steam pressure amplification

Forest Products

Steam System Basics

Master your semester with Scribd collected in a condensate well, and pumped into & The York the New condensate returnTimes system. Barometric condensers rely onOnly direct contact between the coolSpecial offer for students: $4.99/month. ing water and the steam. In petroleum refining

  sep feedstocks into various components. This Not useful in the boili  Useful  tion process relies on differences Cancel anytime. points of these hydrocarbon components. Frac ating towers use a furnace to heat crude oil a


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Steam Syste manufacturing, textiles, and food processing industries also use large amounts of steam for drying. Dryers can be indirect or direct. Indirect dryers remove moisture thermally as energy is transferred from condensing steam, flue gases, or high temperature process fluid to the product being dried. Common indirect dryer types are coil and rotating drum. Direct dryers use hot gases that have been heated with steam or flue gases to directly contact and dry a product. Dryers, like evaporators, can be arranged in multiple-stage configurations. Multiple-stage steam dryers use a cascading set of steam pressures, allowing steam released from an upstream stage to supply steam to the next stage. In many multiple-stage dryers, thermocompressors are used to increase the steam pressure of downstream-effect stages.

Evaporators Evaporators reduce the water content of a liquid, generally by heating it with steam in order to concentrate the product. Evaporators are used extensively in industries such as food processing, chemical manufacturing, steel, forest products, and textiles. N

In most cases, evaporators are shell and tube heat exchangers with the steam on the shell side and the product being concentrated in the tubes. Evaporators can be single effect or multiple effect. A single-effect evaporator uses steam at one set of pressure and temperature conditions to boil off the vapor from a product. Multiple-effect evaporators take the vapor produced from one evaporator and use it to heat the product in a lower-pressure evaporator. Multiple-effect evaporators are generally more efficient at concentrati concentrating ng a fluid than single-effect evaporators. Special offer for students: Only $4.99/month.

Master your semester with Scribd & The New York Times N

Heat Exchangers

basic heat exchanger types are discusse including: I

Tubular

I

Plate and frame

I I

Jacketed Coil.

Tubular heat exchanger. Tubular heat exc

are tube bundles that are surrounded b heated or heating medium. This type o exchanger includes finned tube and sh tube designs as shown in Figure 9. Finn heat exchangers are often used to heat drying and space heating applications. tube heat exchangers are often used fo heating and evaporation. Since the t shell and tube heat exchangers can be to withstand high pressures, sometime ing 1,500 psig, heat exchangers of this often used in high temperature and high applications.

Plate and frame heat exchanger. In plate a

heat exchangers, the two heat exchang are separated by plates. The plates are c or ridged, as shown in Figure 10, to inc surface area available for heat transfer. frame heat exchangers are often used i viscosity applications, where the risk o is less severe. The plate ends are typica by gasketed covers that can be removed disassembly and cleaning. This heat type is used when temperatures and pr moderately low, typically below 300°F an Plate and frame heat exchangers also h  common design variation Read Free Foron 30this Days Sign up to vote titlethat has the welded or brazed together. This  allows  Useful  Not useful temperature Cancelservice anytime. but eliminates the of mechanical cleaning.

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Reformers Steam reformers are used t generate hydrogen, typical from a hydrocarbon feedst such as methane (the larges component of natural gas). turn, hydrogen is used in m petroleum refining and ch cal manufacturing processe Reformers use steam for bo energy and as a source of hydrogen. Steam is injecte with the hydrocarbon feed stock to initiate the follow reaction:

Tubesheet

Sheet Music Tube Side Fluid

Baffles

Shell Side Fluid

Figure 9. Shell and Tube Heat Exchanger

Coil heat exchangers. Coil heat exchangers charac-

teristically use a set of coils immersed in the medium that is being heated. Coil heat exchangers are generally compact, offering a large heat transfer area for the size of the heat exchanger.

Reboilers Reboilers are typically used in distilling processes to increase component separation. Reboilers use heat, often provided by steam, to evaporate the volatile components of a product that has been drawn from a fractionating tower. These volatile components are sent downstream for further processing. The residual components are sent back into the fractionating tower or sent on to a vacuum distillation process. There are several types of reboilers, reboilers, including jacketed jacketed kettle, kettle, kettle, internal reboiler, and thermosyphon reboiler. These designs differ from one another in the way the product is heated with steam. N


CH4

+

Methane

H2O Steam

¡

CO

+

3H

Carbon Hydr monoxide

Reformers often have secondary stages that a used to convert the carbon monoxide to carb dioxide and additional hydrogen. Although l amounts of steam are used throughout the reforming processes, steam is also generated the reformers and is sometimes exported for other uses.

Steam Ejectors Steam ejectors use steam flow through a noz to create a vacuum (similar in operation to t mocompressors). They are used in several diffe types of system applications and process equ ment. Low-pressure conditions promote the evaporation of liquids at reduced temperatur  Read Free Foron 30this Days Sign up to vote title N

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Steam Syste Consequently, many chemical manufacturing Consequently, processes use steam ejectors to increase the concentration of a product. In petroleum refining, steam ejectors are commonly used in the vacuum distillation of heavy hydrocarbon products. Steam ejectors are also used to initiate and maintain vacuum condition in the condensers of condensing turbines.

Steam Injectors Steam injectors are used to inject steam directly into a tank or a pipe containing a process fluid, generally for heating purposes. Many injector types use a nozzle and a diffuser to pull process fluid into the steam before the mixture is injected into the process fluid, to promote an even distribution of heat. Important performance characteristics of injectors include accurate control of the amount of steam injected and effective mixing of the steam and process. N

N

Steam Turbines Steam turbines are used to drive electric generators or other rotating machinery such as compressors, pumps, and fans. Steam turbines are used in many different system designs, depending on the relative requirements for steam, electricity, or other mechanical loads. Steam turbines provide an effective means of stepping down steam pressure while extracting mechanical work. Additional information regarding steam turbines is available in Steam Tip Sheets Numbers 15 and 21 titled Benchmark titled Benchmark the Fuel Costs of Steam Generation and Consider Steam Turbine Drives for Rotating Equipment , found in Appendix B.

Master your semester with Scribd Some turbines have interstage take-offs that & The New York Times allow steam to be extracted at various pressures Special offer forbefore students: Only $4.99/month. reaching the turbine exhaust. These

extractions provide flexibility in meeting com-

for other services. By extracting mecha from steam, backpressure turbines can an efficient means of supplying lowersteam from a high-pressure header.

Condensing turbines. Condensing turbin

steam to vacuum (sub-atmospheri (sub-atmospheric) c) co This steam is condensed in a heat exch referred to as a condenser, and transfer condensate return system. Condensing typically require a source of cooling wa condense the steam.

Strippers Steam strippers are used to remove con from a solution. Strippers are common in petroleum refining and chemical ma ing applications, where process solutio components that have different boiling and removal of one or more of the com is necessary. Injecting steam into the p solution lowers the partial pressure of components, allowing some of them to and get transported away with the stea can also raise the temperature of the m lowering the solubility of the objection rial and causing it to strip off with the Often, the steam and the contaminant densed and separated, allowing recover condensate and disposal or further pro the contaminant. N

Thermocompressors Thermocompressorss combine high-pre Thermocompressor low-pressure steam to form an interme pressure steam supply (see Figure 12). O  low-pressure steam does not have enou Read Free Foron 30this Days Sign up to vote title  to be feasibly used; however, Nothowever useful , dischargin  Useful  Cancel anytime. condensate return system can be an energy loss. Thermocompressors use a sure steam source to recover the energy N

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Steam System Basics

Motive Steam (high pressure)

Discharge (intermediate pressure)

Suction (low pressure)

Figure 12. Thermocompressor Operation

Desuperheaters. The purpose of a desuperheater

is to remove the superheat from steam. The majority of heating and process equipment performs more efficiently using saturated rather than super-heated steam. Desuper-heaters inject a very fine mist of high-purity water, such as condensate, into the steam flow flow.. The superheated vapor gives up heat to the water mist, and by doing so, reduces its temperature temperature..

ence between air and steam When exposed to the lowe temperature air in the syste side, the vent opens. As the higher temperat temperature ure steam es the vent, it closes, preve ing the escape of steam.

Traps. Steam traps are impo

to the performance of endequipment. Traps provide f condensate removal with li or no steam loss. If the trap not function properly, exce steam will flow through th end-use device or the cond sate will back up into it. Ex steam loss will lead to costly operation while condensate backup will promote poor perfor ance and may lead to water hammer. Traps ca also remove non-condensable gases that redu heat exchanger effectiveness. There are sever different types of steam traps, which are discussed in the Distribution section of this Sou book.

Insulation End-use equipment, such as heat exchangers and turbines, should generally be insulated d to the significant heat loss that the surface a of this equipment can provide. The various t of insulation are discussed in the Distributio section of this Sourcebook. Where end-use equ ment requires frequent inspection or maintena removable insulation should be considered.

N

Vacuum breakers. Vacuum conditions can develop

in a steam system when steam flow into a component or a branch is throttled or shut off. If the rate of downstream steam use exceeds the steam supply,, the pressure decreases and vacuum condisupply tions can form. Vacuum conditions also result when the load on the heat exchanger is significantly less than the heat exchanger capacity. If the pressure in the heat exchanger drops too far, the condensate will not drain from the trap due to a higher pressure on the trap’s downstream side. If uncorrected, the condensate level will rise for in students: the heatOnly exchanger exchanger, , reducing the available Special offer $4.99/month. heat transfer area and increasing the risk of


 Additional Equipment Read Free Foron 30this Days Sign up to vote title  The additional equipment category refers to Useful Not useful   Cancel anytime. uses throughout industry, which, though stil significant users of steam, generally account less steam energy than the key IOF end uses. N

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Steam Syste refrigerant pressure. Once it is at the higher pressure, the absorbent/ refrigerant solution is heated, often with steam, which releases the refrigerant. Although absorption chillers generally have lower coefficients of performance (COP) (indicating lower thermodynamic efficiency) than traditional chillers, they use less electric power per ton of cooling and are well suited for use with steam systems. Humidifiers. Humidifiers inject steam into an air

or other gas source to increase its water vapor content. In humidification, steam is used as a source of both water and energy. Humidification applications are found in the chemical manufacturing industry where control of ambient temperature and moisture content are critical for product quality. Preheat/Reheatt air handling coils. Steam is often Preheat/Rehea

used in space heating applications to preheat and reheat air. In many HVAC systems, the conditioned air must have both its temperature and humidity adjusted. In preheat applications, steam is used to heat an air supply, which is typically a mixture of return air and outside air. The air is then conditioned to achieve a certain humidity and temperature. In reheat applications, the air is cooled to a particular dew point to remove water and achieve a desired humidity. As a result, before the air is delivered back to the workspaces, steam coils must reheat the process air stream up to the proper temperature. In both reheat and preheat applications, finned tube heat exchangers are generally used. Tracing. In tracing applications, steam is used to Master your semester with Scribd maintain the temperature of a fluid in a pipe. A common application of tracing lines is to & The New York Times prevent the freezing of a process fluid in piping

Special offer forthat students: $4.99/month. runs Only outside of a temperature controlled

area. Since tracing lines are exposed to freezing

Recovery

The recovery components of a steam sy collect and return condensate back to t tion part of the system. Condensate re provides thermal and water treatment Condensate that is not returned must b pensated for by the addition of makeup which is generally much cooler than co Condensate temperature often exceeds while makeup water temperature is typ between 50°F and 80°F. As a result, the difference between condensate and ma water is generally over 120 Btu/lb, an a of energy that is often more than 10% energy in the boiler generated steam.

Additionally, makeup water is generally with chemicals that remove minerals a lish certain pH levels in the boiler wate the system. Reducing the amount of m water added to the system reduces che Additionally, some of the treatment ch that are contained in condensate are pr to a plant’s wastewater treatment facil trial steam plants often extend across la Recovering condensate from steam sys requires piping, collecting tanks, pump ment, and, in many cases, flash steam meters, and filtration/cleanup equipme ever, the cost savings available from av purchase, treatment, and heating of m water often make investments in conde recovery systems highly feasible.

For more information on condensate r see the Steam Tip Sheet Number  8 title Read Free For 30 Days Sign up to vote on this title Condensate to the Boiler , providedin Ap  Useful  Not useful Cancel anytime. N Condensate Return Piping Condensate return piping transports co

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Insulation Insulation provides energy savings and safety benefits. In terms of energy savings, insulation reduces heat loss from the condensate piping and recovery equipment surfaces, which can make the surrounding work environment more comfortable. Reducing this heat loss can also reduce the burden on the cooling systems that support surrounding workspaces. In terms of safety, insulation reduces the outer surface temperature of the piping, which lessens the risk of burns. Important insulation properties and characteristics of piping insulation are discussed in the Distribution section of this Sourcebook. Condensate Receiver Tanks Condensate receiver tanks collect and store condensate. These tanks are usually located remotely around the condensate system and are configured in conjunction with condensate pumps, as shown in Figure 13. Condensate flows can be highly variable due to changes in steam demand, especially during system start-ups. Receiver tanks minimize the effects of this flow variability on condensate pumps by providing storage, which maintains a minimum water level that prevents downstream condensate pumps from running dry. Since many condensate pumps are centrifugal types, it is important to keep a certain suction pressure to prevent cavitation damage. By maintaining a minimum condensate level, receiver tanks provide enough static pressure to avoid cavitation.

Inlet

Condensate Pump

Condensate Receiver Tank

Figure 13. Condensate Receiver Tank and Pump Combination

N

Most systems also contain a large condensate receiver tank that collects all the condensate returned from the system. This tank may also be used to store pretreated water.

Master your semester with Scribd & The New York Times Special offer for students: Only $4.99/month. N Condensate Pumps

Condensate pumps move condensate from receiv-

Condensate pumps also can be important to performance of end-use equipment. Effective of condensate pumps can eliminate condens back up into end-use equipment, improving process control and reducing potential equipm problems from condensate acidification and water hammer.

Flash Steam Vessels Flash steam vessels allow the recovery of stea from condensate lines, as illustrated in Figur By removing steam from the condensate sys flash steam vessels provide an efficient sourc steam to low-pressure end uses. For example 250°F condensate has a saturation pressure o about 15 psig. Consequently, steam that is separated by flash steam vessels can be used low-pressure steam applications such as spac heating and preheating.  Read Free Foron 30this Days Sign up to vote title For more information on flash steam  vessels Useful Not useful Tip  the Steam Sheet Number 12 titled titled Flash Flash H Cancel anytime. Pressure Condensate to Regenerate Low-Pressure Steam provided in Appendix B. N

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Steam Syste

Saturated Vapor Supply

Sheet Music

Low-Pressure Flash Vessel

High-Pressure Condensate Steam Trap

Saturated Vapor

Level Controller

Saturated Liquid

Condensate Discharge

Figure 14. Flash Steam Recovery Vessel

that are either carried over from the boiler or that form in carbon steel piping and on copper alloy heat exchange surfaces. Although strainers and filters are used to catch the particulate matter,, some contaminants are dissolved in the matter condensate and can cause problems if returned to the boiler. In systems that require a high level of cleanliness, condensate polishers are used. Condensate polishers use ion exchange to remove these contaminants, preventing the redeposition of these contaminants on boiler surfaces.



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Steam System Basics



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Performance Improvement Opp

Section 2: Performance Improvement Opport Overview This section of the Sourcebook discusses important factors that should be considered when industrial facilities seek to improve steam system performance and to lower operating costs. Improving steam system performance requires assessing the entire system, identifying opportunities, and selecting and implementing the most feasible projects. In turn, this requires a systems approach. Similarly, proper selection of the best projects requires quantifying the benefits and costs of each project. Successful implementation of these projects requires the participation of all system stakeholders including production, maintenance maintenance,, and management. Generally, obtaining management participation requires communication of the analyses in economic terms. To address these considerations, this section of the Sourcebook discusses: I The systems approach I

Common performance improvement opportunities

I

Resources that can help identify and assess opportunities

I

The economics related to steam system improvements.

Master your semester with Scribd Systems Approach & The New York Times

the$4.99/month. many industrial uses for steam, Special offer forBecause students:of Only there are wide ranges of steam system sizes, con-

equipment. Similarly, a common engine approach is to break a system down into components or modules, optimize the s the design of these components, and th ble these components to form the syste advantage to this approach is that it sim problems. However, a disadvantage is th overlooks the interaction of these comp contrast, a systems approach evaluates t system to determine how the end-use req can be most effectively and efficiently se

A systems approach also recognizes tha efficiency, reliability, and performance related. For example, an efficiency loss heat loss across uninsulated pipe surfac energy available to the end uses and re boilers to work harder to meet a given Often, energy losses create additional s stresses that accelerate wear and that ca loads for which the system was not ori designed.

Common Performanc Improvement Opportuni

Several steam system improvement opp are common to many industrial  faciliti Read Free For 30 Days Sign up to vote this title opportunities canon be categorized accord  part the system in useful which they are im ofUseful  Not Cancel anytime. ed. Common performance opportuniti generation, distribution, distribution, and recovery steam system are listed in Table 2.

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Performance Improvement Opportunities

Table 2. Common Performance Performance Improvement Opportunities for the Generation, Distribution, and Recovery Parts of Industrial Steam Systems Opportunity

Description Generation

Minimize excess air

Reduces the amount of heat lost up the stack, allowing more of the fuel energ to be transferred to the steam

Clean Cle an boi boiler ler hea heatt tran transfe sferr surf surface acess

Promot Pro motes es eff effect ective ive hea heatt tran transfe sferr from from the com combus bustio tion n gase gasess to to the the ste steam am

Instal Inst alll he heat at re reco cove very ry eq equi uipm pmen entt (feeed (f edwa wate terr eco econo nom miz izer erss and and//or combustion air preheaters)

Recove Reco vers rs av avai aila labl blee he heat at fr from om ex exha haust ust ga gase sess an and d tr tran ansf sfer erss it ba back ck in into to the syst sy stem em by pr preehe heat atin ing g fee feedw dwat ater er or co com mbu bust stio ion n air air

Improvee water Improv water treat treatmen mentt to minim minimize ize boiler blowdown

Reduce Red ucess the amoun amountt of total total disso dissolve lved d solids solids in the the boile boilerr water water, whi which ch allow allowss less blowdown and therefore less energy loss

Rec ecov over er en eneerg rgyy fro from m bo boil ileer blowdown

Tran ansf sfer erss the the av avai aila labl blee ene energ rgyy in in a bl blow owdo down wn st stre reaam bac backk int intoo the the sy syst stem em,, thereby reducing energy loss

Add A dd//re rest stor oree boi boile lerr ref refra raccto tory ry

Red educ uces es he heat at lo loss ss fr from om th thee boi boile lerr and and re rest stor ores es bo boil iler er ef effi fici cieenc ncyy

Optimize deaerator vent rate

Minimizes avoidable loss of steam Distribution

Repair steam leaks

Minimizes avoidable loss of steam

Minimize vented steam

Minimizes avoidable loss of steam

Ensure Ensu re th that at st stea eam m sy syst stem em pi pipi ping ng,, valves, valve s, fittin fittings, gs, and vessels vessels are are well insulated

Redu Re duce cess ene energy rgy lo loss ss fr from om pi pipi ping ng an and d equ equip ipme ment nt sur surfa face cess

Implement Implem ent an eff effect ective ive ste steamam-tra trap p maintenance program

Reduce Red ucess passag passagee of of live live ste steam am int intoo cond condens ensate ate sys system tem and pro promot motes es eff effici icient ent operation of end-use heat transfer equipment

Isol Is olat atee ste steam am fr from om un unus used ed liline ness

Mini Mi nimi mize zess avo avoid idab able le lo loss ss of st stea eam m and and re redu duce cess ene energy rgy lo loss ss fr from om pi pipin ping g and and equipment surfaces

Utilizee backpr Utiliz backpress essure ure turbi turbines nes inste instead ad of PRVs

Provides Provid es a more more efficie efficient nt method method of redu reducin cing g steam steam pressu pressure re for lowlow-pre pressu ssure re services Recovery

Opti Op timi mize ze co cond nden ensa sate te re reco cove very ry Reco Re cove vers rs th thee the therm rmal al en ener ergy gy in th thee con conde dens nsat atee and and re redu duce cess the the am amou ount nt of Master your semester with Scribd  makeup water added to the system, system, saving energy and chemicals teatment Read Free Foron 30this Days Sign up to vote title  e hi highgh-pr pres essu sure re co conde ndens nsate ate to Expl Ex ploi oits ts th thee ava availilab able le en ener ergy gy in th thee re retu turn rnin ing g con conde dens nsat atee & TheUsUse New York Times Useful Not useful   make low-pressure steam

Special offer for students: Only $4.99/month.

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Performance Improvement Opp 1. Introduct Introduction—p ion—provid rovides es instruction instructionss on how to use the guide and what is indicated by the results. 2. Basic data—pr data—prompts ompts the the user to answer answer general general questions such as the amount of fuel used, amount of steam generated, and other general system data. 3. System profili profiling—asse ng—assesses sses how how the user user tracks steam costs, benchmarks steam use, and measures important general operating parameters. 4. Operatin Operating g practices practices of the total total system— system— queries the user regarding practices such as trap maintenance, water treatment, insulation condition, leak repair, and general equipment inspection. 5. Operatin Operating g practices practices of the boiler boiler plant— plant— queries the user on boiler efficiency, heat recovery equipment, steam quality, and general boiler operation. 6. Operating practices of the the distribution, distribution, enduse, and recovery portions of the steam system—queries the user about the use of pressure reducing valves, condensate recovery, recovery, and the use of condensate to generate lowpressure steam. 7. Summary Summary sheet—pro sheet—provides vides scores scores based based on user responses.

Steam System Survey Guide The Steam System Survey Guide is a reference document that is intended for use by plant energy managers and system operations personnel. The Survey Guide provides a technical basis for identifying and assessing many potential steam system improvement opportunities. Although several of these opportunities can be identified survey guide, others require Special offer fordirectly students:with Onlythe $4.99/month. more sophisticated measurements and data N


The Web Web site also also offers links to other r that can assist end users in improving formance and efficiency of their energy utility systems.

Steam System Assessment Tool The Steam System Assessment Tool allo to assess potential savings from individ steam system improvements. Users m data about the condition of their plant Steam System Assessment To Tool ol generat of various improvement scenarios. Resu the energy, energy, cost, and emissions savings variety of improvements could achieve N

The tool contains all the key features o steam systems—boilers, backpressure tu condensing turbines, deaerators, letdow vessels, and feedwater heat exchangers model analyzes boiler efficiency efficiency,, boiler down, cogeneration, steam cost, conde recovery, heat recovery, vent steam, in efficiency,, alternative fuels, backpressu efficiency bines, steam traps, steam quality, and s leaks.

3E Plus Insulation Appraisal Softwar Because insulation is used in every stea its restoration, replacement, or installa common improvement opportunities. awareness regarding the energy losses a associated costs often results in a low p tion of restoring or properly installing on steam system surfaces. As a result, a program known as 3E Plus was develop the North American Insulation Manufa  Association The Read Free Foron 30this Days Sign up to(NAIMA). vote title program inc awareness among steam system  operati  Useful  Not useful management personnel of the benefits Cancel anytime. tion and assists these stakeholders in a insulation opportunities. N

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Performance Improvement Opportunities by region, estimating how difficult the installation process will be based on general piping characteristics. Users can quickly determine the economic feasibility of various insulation thicknesses. Since the program also allows the user to evaluate various combinations of insulation types, 3E Plus can help the user optimize the material thicknesses within an insulation system. Download 3E Plus from the BestPractices Web site at www.eere.energy.gov/industry/bestpractices.

NIA’s Insulation Energy Appraisal Program (IEAP) The National Insulation Association (NIA), an ITP Allied Partner, has developed a training program that offers certification to professionals who conduct insulation appraisals or specify insulation requirements. This program is intended to provide credibility to insulation professionals and to increase consistency of the message that is presented to clients. This program has four key components: I Awarene Awareness ss Building—an important way to increase awareness of the potential cost savings from insulation projects is to effectively promote insulation appraisal as a professional service. N

I

Information Gathering—determining the parts of the system that have the most attractive insulation improvement opportunities usually requires input from the plant personnel. Improving the interview techniques of insulation professionals can increase the usefulness of these assessments.

3E Plus—the 3E Plus program is an important tool for insulation professionals and specifying engineers. Learning to effectively use this tool can improve the quality of the assessment findings, presentation of recommendations, and specificatio specification n of new insulation. Special offercost-effective for students: Only $4.99/month. I Reporting—accur Reporting—accurately ately and effectively reportI


opportunities, ITP has developed steam tip through its BestPractice BestPracticess activities.

These steam tip sheets provide concise descrip of common improvement opportunities. Beca BestPractices continues to develop and identify energy improvement improvement programs, additiona additionall tip sheets are expected. Steam tip sheets availabl this Sourcebook’s Sourcebook’s publication date can be in Appendix B. Additionally, steam tip sheet be found on the BestPractices Web site at www.eere.energy.gov/industry/bestpractices/.

Steam System Training

Steam End User Training This 1-day course covers the operation of typ steam systems and discusses methods of syst efficiency improvement. The training is desig for plant personnel, such as energy manager steam system supervisors, engineers, and equ ment operators, who have steam system resp sibilities in industrial and institutional plant The course covers three key areas of potentia system improvement: N

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Steam Generation Efficiency

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Resource Utililization Effectiveness

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Steam Distribution System Losses

The course introduces the Steam System Sco Tool and the Steam System Assessment Tool, both developed by DOE's BestPractices and u the Steam System Survey Guide as a technica reference. The training also introduces the 3E Plus insulation appraisal software and a cour example is presented that uses this software.  Read Free Foron 30this Days Sign up to vote title  N Steam Specialist Qualification Training Useful Not useful Tool  Cancel anytime. Industry professionals can earn recognition a Qualified Specialists in the use of the BestPract

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Performance Improvement Opp specialists who are interested in becoming proficient in using the BestPractices Steam Tools. To successfully complete the Specialist Qualification Training course, a participant must understand the full suite of BestPractices Steam tools including: I

Steam System Survey Guide

I

Steam System Scoping Tool – Accurate collection and input of data for use with the tool – Appropriate utilization of the software – Interpretation of the software results

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Steam System Assessment Tool – Accurate collection and input of data for use with the tool

difficult than the actual engineering be concept. The corporate audience will re more readily to an economic impact th discussion of Btu, pounds of steam, and ratios. By adopting a financial approac facility manager relates steam efficienc rate goals. Collaboration with financial yield the kind of proposal that is need convince corporate officers who have t word about capital investments such a system upgrades.

Before laying out some recommendatio how to justify steam improvement pro useful to understand the world as the c office usually sees it.

– Development of representative system models – SSAT limitations – Individual project identification – Development of practical methods to accomplish the appropriate projects I

3E Plus – Accurate data gathering for basic insulation related evaluations – Development of evaluation techniques related to common insulation evaluations.

Class participants will receive a Prerequisite Test/Study Test /Study Guide before attending the class. This Study Guide provides an indicator of the skill levels necessary to successfully complete the Specialist Qualification training. Completion of this Study Guide is highly recommended, but is not a requirement to take the training. Completion of BestPractices Steam End User training is also recommended prior to participating in the Specialist Qualification training class, which Special offer forcovers students: $4.99/month. theOnly majority of the Specialist Qualification training prerequisites.


Understanding Corporate Priorities Corporate officers are held accountable executive, a board of directors, and an (or shareholders, if the firm is publicly It is the job of these officers to create a the equity value of the firm. The corpo industrial facilities do so by generating that exceeds the cost of owning and op the facility itself. Plant equipment—inc steam system components—is an asset generate gener ate an economic return. return. The annu ings attributable to the sale of goods pr these assets, divided by the value of th assets themselves, describe the rate of assets. This is a key measure by which decision-makers are held accountable. N

Financial officers seek investments tha certain to demonstrate a favorable retu  inves assets. faced multiple Read Free Foron 30with Days SignWhen up to vote this title  tho opportunities, the officers will favor Useful Not useful   that lead Cancel to both the largest and fastest anytime.

This corporate attitude may impose (so

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Performance Improvement Opportunities energy consumption and cutting noxious combustion emissions.

Measuring the Dollar Impact of Steam Efficiency Steam efficiency improvements can move to the top of the list of corporate priorities if the proposals respond to distinct corporate needs. Corporate challenges are many and varied, which in turn open up more opportunities to “sell” steam efficiency as a solution. Steam systems offer many opportunities for improvement; the particulars are shared elsewhere in this Sourcebook. Once the selections are made, the task is one of communicating the proposals in corporate financial language. N

The first step is to identify and enumerate the total dollar impact of a steam efficiency measure. One framework for this is known as “life-cycle cost analysis.” These analyses capture the sum total of expenses and benefits associated with an investment. The result—a net gain or loss on balance— can be compared to other investment options or to the anticipated outcome if no investment is made. As a comprehensive accounting of an investment option, the life-cycle cost analysis for a steam efficiency measure would include projections of:

N

Financing Steam Efficiency Improvements As with any corporate investment, there are many ways to measure the financial impact steam efficiency investments. Some methods more complex than others are, and proposal may use several analytical methods side-by-s The choice of analyses used will depend on t sophistication of the presenter and the audie

A simple and widely used measure of project economics is the payback period. This is defi as the period of time required for a project to “break even.” It is the time needed for the ne benefits of an investment to accrue to the po where they equal the cost of the initial outla For a project that returns benefits in consiste annual increments, the simple payback equa the initial investment divided by the annual efit. Simple payback does not take take into acco the time value of money; in other words, it makes no distinction between a dollar earned today versus a dollar of future (and therefore uncertain) earnings. earnings. Still, the measure measure is eas use and understand and many companies us simple payback for a quick “go/no-go” decisi on a project. Five important factors to remem when calculating a simple payback:

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Search and selection costs for seeking an engineering implementation firm

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It is an approximation, not an exact economic analysis

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Initial capital costs, including asset purchase, installation, and costs of borrowing

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All benefits are measured without considering their timing

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Maintenance costs

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Supply and consumable costs

All economic consequences beyond the payback are ignored

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Payback calculations will not always find best solution (for the two reasons immed  above) when choosing among Read Free Foron 30this Days Sign up to vote title several pro  options Not useful  Useful  Cancel Payback does notanytime. consider the time value money or tax consequences.

Energy costs over the economic life of the implementation

Master your semester with Scribd Depreciation and tax impacts & The Scrap New York Times value or cost of disposal at the end of I

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Special offerthe for students: Only $4.99/month. equipment’s economic life I

Impacts on production such as product

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Performance Improvement Opp initial investment outlay. outlay. This discount rate can be compared to the interest rate at which a corporation borrows capital.

I

Reduced cost of environmental com Facility managers can proactively see the corporation’s exposure to penalt to environmental emissions complian efficiency,, as total-system discipline efficiency better monitoring and control of fu Combustion emissions are directly r fuel consumption; they rise and fal tandem. By implementing steam ef the corporation enjoys two benefits fuel expenditures per unit of produc fewer incidences of emission-related

I

Improved worker comfort and safety system optimization requires ongoin toring and maintenance that yields and comfort benefits in addition to savings. The routine involved in sy monitoring will usually identify ope abnormalitiess before they present a abnormalitie plant personnel. Containing these d precludes threats to life, health, and

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Improved reliability and capacity Another benefit to be derived from efficiency is more productive use of assets. The efforts required to achiev maintain energy efficiency will larg tribute to operating efficiency. By en the integrity of steam system assets, ty manager can promise more reliab operations. The flip side, from the c perspective, is a greater rate of retur assets employed in the plant.

Many companies set a threshold (or hurdle) rate for projects, which is the minimum required internal rate of return for a project to be considered viable. Future benefits are discounted at the threshold rate, and the net present worth of the project must be positive in order for the project to be a “go.” N

Relating Steam Efficiency to Corporate Priorities Saving money should be a strong incentive for adopting steam efficiency. efficiency. Still, that may not be enough for some corporate observers. The facility manager’s case can be strengthened by relating a positive life-cycle cost outcome to specific corporate needs. Some suggestions for interpreting the benefits of fuel cost savings include the following (finance staff can suggest which of these approaches are best for the current corporate climate): I

A new source of permanent capital. Reduced fuel expenditures—the direct benefit of steam efficiency—can be thought of as a new source of capital for the corporation. The investment that makes this efficiency possible will yield annual savings each year over the economic life of the improved steam system. Regardless of how the steam efficiency investment is financed—borrowing, financed—bor rowing, retained earnings, or third party financing—the annual savings will be a permanent source of funds as long as the steam efficiency savings are maintained on a continuous basis.

Master your semester with Scribd Added shareholder value. Publicly held corporations usually embrace opportunities to & The New York Times I

enhance shareholder Special offer for students: Only $4.99/month.value. Steam efficiency can be an effective way to capture new value.

Call to Action A proposal for steam efficiency implem can be made attractive to corporate dec  Read Free For 30 Days Sign up to vote on this title makers if the facility manager:  Useful opportunities  Not useful for achievin Identifies I  Cancel anytime. efficiency N

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Determines the life-cycle cost of atta

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Performance Improvement Opportunities N

Summary Increased awareness of the potential improvements in steam system efficiency and performance is an important step toward increasing the competitive capabilities of energy-intensi energy-intensive ve industries. Some of the useful steam resources and tools developed by BestPractices have been described in this section. Additional steam resources and tools and where to obtain them are described in the Resources and Tools section of this Sourcebook.



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Where to

Section Sec tion 3: 3: Where Where to Fin Findd Help Help This portion of the Sourcebook lists resources that can help end users increase the cost-effective performance of steam systems. The section is organized into three sections, described below:

Programs This section describes the U.S. Department of Energy’s Industrial Technologies Program (ITP) BestPractices activity activity,, a national effort aimed at improving the performance of industrial steam systems. This section provides a list of associations and other organizations involved in the steam system marketplace. N

Contacts This section provides a list of associations and other organizations involved in the steam system marketplace. N

Resources This section provides information on books and reports, other publications, government and commercial statistics and market forecasts, software, training courses, and other sources of information that can help end users make informed steam system equipment purchase and system design decisions. N

The advancement of energy- and proces technologies is complemented by ITP’ management best practices for immedia results. ITP’s BestPractices assists the ei tries of the Future—aluminum, chemic products, glass, metal casting, mining, and steel—to identify and realize their their efficiency and pollution prevention op a system and life-cycle cost perspective activities such as plant-wide energy ass implementation of emerging technolog energy management of industrial syste Practices delivers energy solutions for i that result in significant energy and co waste reduction, pollution prevention, enhanced environmental performance

Plant Assessments Depending on the industry, energy can for 10% or more of total operating cost assessments identify opportunities for im ing new technologies and system impro Many recommendations from energy a ments have simple payback periods of 18 months and can result in significan savings. N

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Plant-wide assessments help manufa develop comprehensive plant strate increase efficiency, efficiency, reduce emission  Read Free Foron 30this Days Sign up to vote title boost productivity. Annual competi  Useful offer Not useful  solicitations a 50% cost share o Cancel anytime. $100,000 in matching funds.

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Small- to medium-sized manufactur

Master your with Scribd Thesemester Industrial Technologies and BestPractices & The NewProgram York Times Overview Special offer forNstudents: Only $4.99/month. Industrial manufacturing consumes 36% of all

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Where to Find Help By sharing implementation and providing thirdparty validation and verification of performance data, the energy, economic, and environmental benefits can be assessed to accelerate new technology to acceptance.

Energy Management ITP encourages manufacturers to adopt a comprehensive approach to energy use that includes assessing industrial systems and evaluating potential improvement opportunities. Efficiency gains in compressed air, motor, process heating, pumping, and steam systems can be significant and usually result in immediate energy and cost savings. ITP offers software tools and training in a variety of system areas to help industry become more energy and process efficient, reduce waste, and improve environmental performance. N

Allied Partnerships Allied Partners are manufacturers, associations, industrial service and equipment providers, utilities, and other organizations that voluntarily work with ITP. Allied Partners seek to increase energy efficiency and productivity for those industries that participate in endorsing and promoting ITP programs, products, and services. N

Allied Partnerships help ITP achieve industrial energy efficiency goals by extending delivery channels through the partners’ existing networks. In turn, partners realize benefits, such as achieving their own corporate, institutional, or plant goals and objectives by expanding services to customers and suppliers. Allied Partners also gain access to technical resources, such as software, technical publications, and training; and they can gain recognition as leaders in the implementation of energy-efficient technologies and practices. Special offer students: Only Partnerships, $4.99/month. contact the For for more on Allied EERE Information Center at 877-337-3463.


ing out what’s available from EERE and ITP. C tact the EERE EERE Info Informat rmation ion Cent Center er at 877-33 877-33 or www.eere.energy.gov/informationcenter. ITP and BestPractices Web Sites. The ITP and

BestPractices Web sites offer a large array of information, products, and resources to assis manufacturerss who are interested in increasi manufacturer the efficiency of their industrial operations. You can gain access to Web pages for the eig Industries of the Future, learn about upcomi events and solicitations and much more through the ITP site. Visit the ITP site at www.eere.energy.gov/industry.

The BestPractices site offers case studies of companies that have successfully implemen energy efficient technologies and practices, software tools, tip sheets, training events, and solicitations for plant assessments. You can see these and other resources at www.eere.energy.gov/industry/bestpractices.

Industrial Energy Savers Web site. Manufacturers

will find a number of resources on this site t implement industrial energy efficiency proje and see immediate savings. Access this site a www.eere.energy.gov/consumerinfo/industry.

Training Training sessions in industrial systems impro Training ments using ITP software tools are offered periodically through Allied Partners. Visit t BestPractices Web site for more information www.eere.energy.gov/industry/bestpractices. N

 Software Read Free Foron 30this Days SignTools up to vote title  ITP and its partners have developed several s Useful  Not useful  ware tools for systems improvements to help Cancel anytime. make decisions about implementing efficien practices in your manufacturing facilities. N

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Where to • The NOx The NOx and Energy Assessment Tool (NxEAT) helps plants in the petroleum refining and chemical industries assess and analyze NOx emissions and how the application of energy efficiency improvements can reduce NOx. Perform "what-if" analyses to optimize and select the most cost-effective methods for reducing NOx from systems such as fired heaters, boilers, gas turbines, and reciprocating engines. • The Process Heating Assessment and Survey Tool (PHAST) provides an introduction to process heating methods and tools to improve thermal efficiency of heating equipment. Use the tool to survey process heating equipment that uses fuel, steam, or electricity, and identify the most energy-intensive equipment. You can also perform an energy (heat) balance on selected equipment (furnaces) to identify and reduce non-productive energy use. Compare performance of the furnace under various operating conditions and test "what-if" scenarios. • The Pumping System Assessment Tool (PSAT) helps industrial users assess the efficiency of pumping system operations. PSAT PSAT uses achievable pump performance data from Hydraulic Institute standards and motor performance data from the MotorMaster+ database to calculate potential energy and associated cost savings.

Newsletters • The Industrial Technologies Program E-Bulletin is a monthly e-mail update that spotlights technologies, significant project developments, and program activities; new ITP and BestPractices products; training and events; Web updates; and solicitations. The E-Bulletin The E-Bulletin Special offer for students: Only $4.99/month. provides readers with links to source information on the ITP, BestPractices, and IAC Web N


DOE Steam-Specific Resourc Software: DOE’s Steam System Tool Suite helps potential savings in your facility, facility, by evaluating and steam system improvements.

Steam System Scoping Tool —This —This tool is designed steam system energy managers and operations per form initial self-assessments self-assessments of their steam system will profile and grade steam system operations and ment, and will will help you you to evaluat evaluatee your steam syste against best practices.

Steam System Assessment Tool (SSAT 2.0.0) —This —This users to assess potential savings from individualize system improvements. Users input data about their conditions, and the SSAT generates results detailing cost, and emissions savings that could be achieved 16 different improvements.

3E Plus Version 3.2 —This —This program calculates the mo cal thick thickness ness of industri industrial al insulation insulation for user user input op conditions. You can make calculations using the bu performance relationships of generic insulation mat supply conductivity data for other materials.

Training: Steam Tool Specialist Qualification Trainin professionals can earn recognition as Qualified Qualified Spec use of the BestPractices Steam Tools. DOE offers an i 2-1/2 day training for steam system specialists, inclu of classroom instruction and a written exam. Particip complete the training and pass the written exam ar by DOE as Qualified Steam Tool Specialists. Special assist industria industriall customers in using the BestPractices to evaluate their steam systems.

Newsletter: Steami Steaming ng Ahea d d is is a bimonthly e-mail published by the Alliance to Save Energy that descr activities and information products of the BestPract effort. BestPractices Steam outreach and promotion  Read Free For 30this Days Sign up vote on titleEnergy. Steami performed bytothe Alliance to Save  promotes best-in-classNot practices usefuland technology ap  Useful  Cancel anytime. steam system design and management. Additional on Steaming Ahead can Ahead can be found at: www.steamin

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Where to Find Help

Directory of Contacts Information on improving the performance of industrial energy systems is available from several resources. To To improve the profitability of U.S. industry, ITP’s BestPractices offers many resources for steam system management. These resources complement Industries of the Future technology development programs, which address other industrial systems, such as motor motor,, compressed air, combined heat and power, and process heating, in addition to efforts by the Industrial Assessment Centers. Collectively, Collectively, these efforts assist industry in adopting near-term and long-term energyefficient practices and technologies. For assistance in these areas, contact:

U.S. Department of Energy Industrial Technologies Program BestPractices Steam Room 5-F-065, MS EE-2F 1000 Independence Avenue, SW Washington, DC 20525 Phone: 877-337-3463 www.eere.energy.gov/industry For specific information regarding steam systems, including assistance in locating steam system specialists and equipment vendors, BestPractices Steam provides an excellent set of helpful resources. Together with industrial end users, equipment suppliers, and resource organizations, BestPractices Steam helps industry stay competitive and promotes the comprehensive upgrade of industrial steam systems.

Master your semester with Scribd Alliance to Save Energy 1200 18th Street, NW,Times Suite 900 & The New York Washington, DC 20036 Special offer for students: Only $4.99/month. Phone: 202-857-0666 Fax: 202-331-9588

American Boiler Manufacturers Association (ABMA) 4001 North 9th Street, Suite 226 Arlington, VA 22203-1900 Phone: 703-522-7350 Fax: 703-522-2665 www.abma.com

ABMA is a trade association of manufacturer boilers, related fuel-burning equipment, user boiler and boiler-related equipment, and com nies that provide products and services to th boiler industry.

The ABMA Bookstore is a one-stop source for boiler industry information. Find industry standards, technical references, and more fro ABMA, Underwriters Laboratories, Laboratories, and many other publishers.

Association of Energy Engineers (AEE) 4025 Pleasantdale Road, Suite 420 Atlanta, GA 30340 Phone: 770-447-5083 Fax: 770-446-3969 www.aeecenter.org

AEE is a membership organization organization of over 8,000 professionals in the energy efficiency, utility deregulation, facility management, pl engineering, and environmental compliance fields. AEE offers a variety of outreach progra including technical seminars, conferences, publications, and certification programs.

Association for Facilities Engineering (AFE) Read Free For 30 Days Sign up to vote on this title 8160 Corporate Park Drive, Suite 125  Cincinnati, OH 45242  Useful  Not useful Cancel anytime. Phone: 513-489-2473 Fax: 513-247-7422 www.afe.org

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Where to Council of Industrial Boiler Owners (CIBO) 6035 Burke Centre Parkway, Suite 360 Burke, VA 22015 Phone: 703-250-9042 Fax: 703-239-9042 www.cibo.org CIBO provides information and advocacy to achieve solutions to industrial energy, energy, environmental, and legislative issues and policies. Objectives of CIBO include: 1. Informat Information ion exchang exchangee among member members, s, government, and the public concerning policies, laws, and regulations that affect industrial energy systems. 2. Techn echnicall ically y sound, equitable, equitable, cost-effect cost-effective ive laws and regulations. 3. Improved Improved reliabili reliability ty and cost-effect cost-effectivene iveness ss of industrial energy systems.

NAIMA is a trade association of North manufacturers of fiberglass, rock wool, wool insulation products. NAIMA conc its efforts on promoting energy efficien environmental preservation through th fiberglass, rock wool, and slag wool ins products, while encouraging safe produ use of these products.

STEAM-LIST The STEAM-LIST is a discussion forum motes the exchange of information, pr solving, and discussion of steam generato and equipment. Included among the com and issues that are discussed are boilers feed pumps, water treatment, corrosion scaling, valves, PRVs, traps, turbines, fl ing, heating coils, condensate pumps, heating, and system modeling. This lis ed to promote practical discussions, theoretical or academic discussions.

National Association of Power Engineers (NAPE) 1 Springfield Street Chicopee, MA 01013 Phone: 413-592-6273 www.powerengineers.com

Subscription information can be obtain contacting: [email protected] [email protected] as.edu

NAPE is a professional association for power engineers. NAPE was established in 1879 and provides education and resources on power and energy engineering.

Note: The descriptions accompanying ing sources have generally been taken from the publisher/author/developer of these sources does not imply endors the U.S. Department of Energy.

National Insulation Association (NIA) 99 Canal Center Plaza, Suite 222 Alexandria, VA 22314 Phone: 703-683-6422 Fax: 703-549-4838 www.insulation.org


Special offer for students: Only $4.99/month. NIA is a service organization that promotes the general welfare of the commercial and industrial

Resources and Tools

Several other resources are available th current tools, technologies, and practice help improve steam system operating e  resour andRead performance. Many of these Free Foron 30 Days Sign up to vote this title  the b intended to increase awareness of Not projects useful and to iden  Useful  energy improvement Cancel anytime. the industry professional can go for mo

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Where to Find Help

traps. It also includes Recommendation Charts which summarize findings on which type of trap will give optimum performance in a given situation and why.

ASHRAE 1791 Tullie Circle, NE Atlanta, GA 30329 800-527-4723 www.ashrae.org ASHRAE Handbook of HVAC Systems and Equipme Equipment, nt, 2000 Description: Complete guide to steam systems design and equipment.

Association for Facilities Engineering (AFE) 8160 Corporate Corporate Park Park Drive, Suite 125 Cincinnati, OH 45242 513-489-2473 www.afe.org Boiler Plant and Distribution Optimization Manual Description: Guide for boiler and plant operators to optimize the efficiency of their boilers and distribution systems.

Babcock and Wilcox 20 South Van Buren Avenue Barberton, OH 44203-0351 330-753-4511 www.babcock.com Steam: Its Generation Generation and Use, Use, 40th Edition Description: This book is intended to help design, procure, construct, maintain, and/or operate equipment in a way that will provide reliable performance. Special offer for students: Only $4.99/month.


Boiler Efficiency Institute P.O. Box 2255 Auburn, AL 36831-2255 800-669-6948 www.boilerinstitute.com

Steam Efficiency Improvement Description: An introductory text for establish a program for reducing losses in the use of st The text is divided into three areas: steam transmission, steam consuming processes, an condensate return systems.

CANMET Energy Technology Centre 1 Haanel Drive Ottawa, Ontario Canada K1A 1M1 613-996-8693 www.nrcan.gc.ca/es/etb/cetc/cetchome.htm

An Energy Efficiency and Environment Primer for Boilers and Heaters Prepared by: Federal Industrial Boiler Program CANMET Energy Technology Centre Description: This guide is intended to provide basic discussion of combustion processes, the emissions, and techniques for reducing energ consumption and environmental emissions. ISBN: 0777895366

Council of Industrial Boiler Operators (CIBO) 6035 Burke Centre Parkway, Suite 360 Burke, VA 22015 703-250-9042 www.cibo.org  Read Free Foron 30this Days Sign up to vote title 

Energy Efficiency Handbook  Useful  Not useful Cancel anytime. Description: The Energy Efficiency Handbook w prepared to help owners and operators get the

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Where to Energy Efficiency Manual Author: Donald R. Wulfinghoff Description: A comprehensive treatment of energy efficiency applications in industrial, commercial, and residential settings. Industrial boiler operators will be interested in Section 1, “Boiler Plant,” which devotess 225 pages solely devote solely to steam systems. systems. Dozens of tips are provided, each with an assessment of their potential for savings, rate of return, reliability, and ease of initiation. ISBN: 0965792676

The Fairmont Press 700 Indian Trail Lilburn, GA 30047 770-925-9388 www.fairmontpress.com Efficient Boiler Operations Operations Source Book, Fourth Edition Authors: F. William Payne and Richard E. Thompson Description: Reviews the fundamentals of boiler combustion and the factors that affect boiler efficiency. This book is intended for operators and supervisors of boiler plants. ISBN: 01353226885 Energy Management Handbook Author: Wayne C. Turner Description: This book discusses steam and condensate systems, waste heat recovery, co-generation, and industrial insulation. ISBN: 013728098X Handbook of Energy Energy Audits, Fourth Edition Edition Author: Albert Thumann Description: Contains information on boilers, steam traps, insulation, and a chapter on computer software for energy audits. ISBN: 0139752021

Master your semester with Scribd Plant Engineer’s and Manager’s Guide to Energy Conservation, Edition & The New YorkSeventh Times Author: Albert Thumann Special offer for students: Only $4.99/month. Description: Provides information on steam tracing, steam generation using waste heat

The Steam Trap Handbook Author: James F. McCauley Author: James Description: This book is intended for e and technicians to help them optimize performance of their steam systems by on steam traps. This book discusses pro selection and sizing, application, opera and maintenance of steam traps.

International District Energy Associatio 125 Turnpike Road, Suite 4 Westborough, MA 01581-2841 508-366-9339 www.districtenergy.org

District Heating Heating Handbook, Handbook, Fourth Edition Edition Description: A guide for engineers to un district heating and how best to use it.

John Wiley & Sons 111 River Street Hoboken, NJ 07030-5774 201-748-6000 www.wiley.com

Handbook of Energy Systems Engineering Production and Utilization Author: Leslie Wilbur (Editor) Description: This book covers all aspects system engineering from a user’ user’ss persp It presents a holistic approach to unde these systems from fuels to end-use tec for mechanical and electric production utilization in industry today. The exten of references provided are invaluable to interested in energy production  and Read Free For 30 Days Sign up to vote on this title Publication, 1985.   Useful  Not useful Cancel anytime.

Krieger Publishing Company P.O. Box 9542

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Where to Find Help Marcel Dekk Marcel Dekker er,, Inc. 270 Madison Avenue New York, NY 10016-0602 212-696-9000 www.dekker.com

Nalco Company 1601 West Diehl Road Naperville, IL 60563-11 60563-1198 98 877-813-3523 www.nalco.com

Steam Plant Calculations Manual G anapathy Author: V. Ganapathy Description: Provides solutions to nearly 200 practical questions related to the planning, design, operation, and maintenance of steam plant systems.

Nalco Guide to Boiler Failure Analysis Authors: Robert D. Port and Harvey M. Herro Description: This book is a comprehensive fie guide to boiler system failures. It is intended aid in-plant detection and diagnosis. Correct procedures procedur es can usually usually be specified once t cause of system failures has been determined

McGraw-Hill 1221 Avenue of the Americas New York, NY 10020 212-512-2000 www.bookstore.mcgraw-hill.com Marks Standard Handbook for Mechanical Engineers Authors: Eugene Avallone and Theodore Baumeister, III (Editors) Description: Provides descriptions of different heat distributi distr ibution on systems including including low-pressure steam systems. ISBN: 007004997 0070049971 1 A Practical Guide to Steam Turbine Technology Author: Heinz P. Bloch Description: This book is written for plant, mechanical, design, and maintenance engineers, and will assist end users users with selecting, selecting, operating, operating, and maintaining steam-driven systems. It includes design and manufacturing data for steam turbines and compre compressor ssors, s, as well well as the other operational components. component s. ISBN: 007005924 0070059241 1 Shreve's Chemical Process Industries, Process Fifth Edition Master your semester with Scribd Author: G. T. Austin The bookTimes provides an overview of Description: & The New York the chemical processing of raw materials into

Special offer for students: Only $4.99/month. useful and profitable products. It provides process descriptions and diagrams for many

Nalco Water Handbook, Second Edition Edition Author: Frank N. Kemmer (Editor) Description: This reference discusses the use o water and steam in water treatment unit ope tions, the use of water and steam in a numbe major process industries, and specialized wat treatment technologies in boilers and other syst

Pennwell Publishing 1421 South Sheridan Road Tulsa, OK 74112 918-835-3161 www.pennwell.com

Petrochemicals in in Nontechnical Language, Language, Third Ed Authors: Donald L. Burdick and William L. Description: Provides an overview of the key processes and operations in the petrochemic industry.

Petroleum Refining in Nontechnical Language, Third Edition  Read Free Foron 30this Days Author: William L. vote Leffler Sign up to title  anNot overview Description: Useful useful of the key  Provides  Cancel anytime.in the petroleum processes and operations refining industry for professionals in finance and marketing.

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Where to economically practical to recover recover.. Presents detailed heat and material balances developed from the process flow diagrams for 108 industrial processes. Handbook of Industrial Power & Steam Systems Author: Paul Garay Description: Describes the design and operation features of industrial power plants, considering such aspects as environmental concerns, basic energy and steam, electrical systems, heat recovery, energy conservation, codes and standards, and information sources. Publication, 1995. ISBN: 0131474146

Efficient Use of Process Steam Description: This handbook provides a introduction to steam properties, and a awareness of how steam can be success beneficially used in industry. Publicatio

Steam Trapping Principles Description: This handbook explains the of steam trapping, and provides data to select and install steam traps for the be maximum plant efficiency.

Spirax Sarco Application Engineering Department 1150 Northpoint Boulevard Blythewood, SC 29016 803-714-2000 www.spirax-sarco.com

Yarway Corporation/Tyco Valve & Contr 9700 West Gulf Bank Road Houston, TX 72040 713-466-1176 www.yarway.com

Hook-Ups—Design of Fluid Systems Description: The Hook-Up Book is intended to serve as a reference in the design, operation, and maintenance of steam, air, and liquid systems. The book is a learning tool to teach engineers how to design productive steam systems efficiently and cost effectively.

Industrial Steam Trapping Handbook Description: Focuses on good steam pip system/application practices. Includes e information on different steam trap tech condensate line sizing, and steam trap techniques.

Steam Utilization—Design of Fluid Systems Description: The Steam Utilization Book is intended to serve as a reference in steam fundamentals to the most efficient use of steam heat content. The book describes proper steam trapping, controls, and condensate recovery.

TAPPI Press 15 Technology Parkway South Norcross Norc ross,, GA 30092 30092 800-332-8685 www.tappi.org


Cost Reduction in the Pulp and Paper Industry Special offer forEnergy students: Only $4.99/month. Prepared by: Paprican (Canada)

Other Publications (Guides, (Gui des, Manua Manuals, ls, and Stan

American Boiler Manufacturers Associa (ABMA) 4001 North 9th Street, Suite 226 Arlington, VA 22203-1900 703-522-7350 www.abma.com  Read Free Foron 30this Days Signprovides up to vote title ABMA a wide range of  guides, Usefulpublications other  Not useful and on boiler opera Cancel anytime. maintenance.

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Where to Find Help American National Standards Institute (ANSI) Fluid Control Institute of America, ANSI 25 West 43rd Street New York, NY 10036 212-642-4900 www.ansi.org ANSI/Fluid Control Institute 69-1-1989 (revised 1994) Description: Pressure ratings for steam traps. ANSI/Fluid Control Institute 85-1-1994 Description: Standard for production testing of steam traps. ANSI Fluid Control Institute 87-1-1994 Description: Classifications and operating principles of steam traps. Fluid Control Institute 97.1 Description: Standard for production testing of secondary pressure drainers (condensate return pumps).

American Society of Mechanical Engineers (ASME) Three Park Avenue New York, NY 10016-5990 800-843-2763 www.asme.org ANSI/ASME PTC 39.1, Performance Tes Testing ting Description: Reviews all the necessary information to conduct performance tests on steam traps for efficient use of plant steam. ASME B31.1 Power Piping Code 1995 Edition Description: Code of standards for pressure piping.

Master your semester with Scribd ASME Boiler/Pressure Code & The New YorkVessel Times Construction specifications associated Description: Special offer for students: Only $4.99/month. with boilers and their operation.

Armstrong International, Inc. 816 Maple Street Three Rivers, MI 49093 269-273-1415 www.armintl.com

Armstrong Service Guide Bulletin–301 Description: Steam trap installation and mainten

Chart 1101 - A Quick Way to Find How Much Stea You Need to Heat Water Description: Chart showing amount of steam the boiler horsepower required to heat water

Chart 1121 - How to Size Condensate Return Line Description: Sizing condensate return lines pr ents several problems that differ from those sizing steam or water lines. The most signific is handling flash steam. The T he chart contains formulas to size condensate lines and return capacity data.

Installation and Te Installation Testing sting of Inverted Bucket Steam Traps–Bulletin - 307 Description: Steam trap testing for Inverted Bu traps.

Steam Trap Testing Guide for Energy Conservation Description: Trap testing for all trap styles.

ASTM International 100 Barr Harbor Drive West Conshohocken, PA 19428-2959 610-832-9585 www.astm.org

Annual Book Standards 2004, SectionFour, Four, Read Free Foron 30 Days Signofup to vote this title 04.06, “Thermal Insulation: Insulation: Environmental Acoust Useful  Not useful  Cancel anytime. Description: Features specifications that estab property requirements requirements for various types of in tion. Also included are tests, practices, and g

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Where to Recommendations for Treatment of Water for Steam Boilers and Water Heaters (BS 2486:1997) recommendations ns Description: The standard gives recommendatio for the control of waterside conditions in steam boilers and water heaters. It also includes information on the preparation of feedwater required for these systems.

National Board of Boiler and Pressure Vessel Inspectors 1055 Crupper Avenue Columbus, OH 43229 614-888-8320 www.nationalboard.org National Board Inspection Code, ANSI/NB-23 National Board of Boiler and Pressure Vessel Inspectors Description: The purpose of the National Board Inspection Code is to “Maintain the integrity of pressure retaining items after they have been placed into service by providing rules for inspection, repair, and alteration…”

National Insulation Association (NIA) 99 Canal Center Plaza, Suite 222 Alexandria, VA 22314 703-683-6422 www.insulation.org National Commercial and Industrial Insulation Standards Description: This is a national standard for designing, specifying, and installing thermal mechanical insulation for commercial and industrial pipe, equipment, vessels, and ducting systems.

Master your semester with Plant Support Support & Evaluations, Inc. Scribd 282 Shellstone Court & The New Naples,York Florida Times 34119 Special offer for888-615-3559 students: Only $4.99/month. www.plantsupport.com

Process Industry Practices 3925 West Braker Lane (R4500) Austin, TX 78759 512-232-3041 www.pip.org

Process Industry Practices (PIP) is a con process industry owners and engineering tion contractors who serve the industry lishes documents called "Practices." Thes reflect a combination of company engin standards in many engineering disciplin Practices include design, selection and sp and installation information.

Spirax Sarco Application Engineering D 1150 Northpoint Boulevard Blythewood, SC 29016 803-714-2000 www.spirax-sarco.com

Spirax Sarco Products, Products, Applications and the Steam and Condensate Loop “Wall Char Description: Wall chart of a total steam showing steam generation, distribution and recovery guidelines.

Spirax Sarco Specification Guide and Desig Description: Guideline specification and note requirements for industrial, HVAC clean steam systems.

Steam Distribution. Technical Reference Guide ( Description: This guide looks at the dist dry saturated steam as a conveyor of he to the point of use, for either process h  change applications or space heating. I Read Free Foron 30this Days Sign up to vote title  the issues associated Not with usefulthe impleme  Useful  Cancel anytime. of an efficient steam system.

TAPPI Press

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Where to Find Help United Kingdom Energy Efficiency Action Energy Web site Good Practice Guides +44 (0)08 0058 5794 www.actionenergy.co.uk The Action Energy site provides an extensive list of publications on industrial energy efficiency including the following Good Practices Guides:

Guidance for Coal-Fired Boiler Operation Description: Guidelines for boiler operation for boilers fueled by coal. Guidance for Gas-Fired Boiler Operation Description: Guidelines for boiler operation for boilers fueled by gas. Guidance for Oil-Fired Boiler Operation Description: Guidelines for boiler operation for boilers fueled by oil. U.S. Army Corps of Engineers 441 G Street, NW Washington, DC 20314-1000 202-761-0001 www.usace.army.mil Industrial Water Treatment Procedures, PWTB 420-49-5 Description: Guide for boiler plant operators to properly set up, maintain, and control boiler system water chemistry. Applies to boiler systems operating below 600 psi. Includes guidelines for water treatment for other HVAC systems.

Master your semester with Scribd U.S. Department of Energy Information Bridge & The New York Times P.O. Box 62 Special offer students: Only $4.99/month. Oakfor Ridge, TN 37831 888-293-6498

Guide to Combined Heat and Power Systems for B Owners and Operators Description: This guide is a resource to help in try evaluate the viability of cogeneration for n or existing ICI boiler installations. Informatio the guide focuses on technical, economic, and regulatory issues that boiler owners and opera should consider during the planning phase of CHP project. In addition, the guide identifies many of the potential benefits and possible ba ers to successful implementation of cogenerat technology. The guide was developed with th American Boiler Manufacturers Association (AB and the Council of Industrial Boiler Owners (CIBO). Document reference: ORNL/TM-2004

U.S. Environmental Protection Agency Ariel Rios Building 1200 Pennsylvania Avenue, NW Washington, DC 20460 202-272-0167 www.epa.gov

Wise Rules Tool Kit Description: Rules and measures for estimatin potential energy, cost, and greenhouse gas emissions savings with information on boile steam systems, furnaces, process heating, wa heat recovery, cogeneration, compressed air systems, and process cooling.

Software Armstrong International, Inc. 816 Maple Street Three Rivers, MI Read Free Foron 30this Days Sign up to49093 vote title 269-273-1415  Useful  Not useful Cancel anytime. www.armintl.com Armstrong Coil Sizing Software

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Where to Armstrong PRV Sizing Software Developer: Armstrong Internation International al Description: PRV sizing and selection instructions for specific applications. Armstrong Steam Eye Software International al Developer: Armstrong Internation Description: Software designed to constantly monitor steam traps in a system. Armstrong Trap Sizing Software International al Developer: Armstrong Internation Description: Steam trap sizing and selection instructions for specific applications.

ChemicaLogic Corporation 99 South Bedford Street, Suite 207 Burlington, MA 01803 781-425-6738 www.chemicalogic.com SteamTab Software Developer: ChemicaLogic Corporation Description: SteamTab is a tool designed for steam property users in the scientific, engineering, plant operation, and educational communities. SteamTab uses fundamental equations to calculate all steam properties with interpolation or curve fits to raw steam data. SteamTab products support spreadsheet applications.

Conserv-It Software 13000-F York Road, #116 Charlotte, NC 28278 704-841-9550 www.conserv-it.com

Master your semester with Scribd SteamWorks Pro Developer: Conserv-It Software, Inc. & The New York ThisTimes software assists in tracking steam Description: maintenance efforts. Special offer fortrap students: Only $4.99/month.

erators, and thermal oxidizers. Controls i water side for single or three-element dru controls, combustion controls for paralle and cross-limiting of one or more fuels, trim. Steam header pressure controls ar ed, as well as a simulation for training.

EPD 14 Hayes Street Elmsford, NY 10523 800-892-8926 www.epdtech.com

DataTemp 2 Software Developer: EPD Description: DataTemp 2 Software recor and graphs temperature data over time maintenance operations and process m and control, temperature trend data is If that data is in a form you can’t use, a problem. DataTemp 2 provides a sim tion. Using an EPD PM infrared for inp your computer as a data logger and rec DataTemp 2 lets you take accurate tem measurements at programmable time i

Field Data Specialists, Specialists, Inc. 6917 Stennis Blvd. Pascagoula, MS 39581 800-932-9543 www.trapbase.com

TrapBase97 Tr apBase97 for Windows Software Developer: Field Data Specialists, Inc. Description: TrapBase was designed as a f to assist in developing a systematic steam  program. The software has Read Free Foron 30this Days Sign up to vote titlefeatures for d  directed surveys, field reporting, mainten Useful Not useful   work orders/history orders/hi story,, field data analysis, Cancel anytime. results analysis. Existing data from other or from spreadsheets can be imported in

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Where to Find Help Linnhoff March Targeting House Gadbrook Park Northwich, Cheshire CW9 7U3 United Kingdom +44 (0)1606 815100 www.linnhoffmarch.co.uk PROSTEAM Software Developer: Linnhoff March Description: PROSTEAM is an engineering add-in model for a Microsoft Excel spreadsheet. It provides steam and water thermodynamic and transport property proper ty calculations, calculations, and steam steam utility uti lity system systemss modeling.

National Institute of Standards and Technology 100 Bureau Drive, Stop 3460 Gaithersburg, MD 20899-3460 301-975-6478 www.nist.gov NIST/ASME Steam Properties Developer: National Institute of Standards and Technology Description: Database of steam and water thermodynamic properties.

Nelson & Roseme, Nelson Roseme, Inc. P.O. Box 30024 Walnut Creek, CA 94598 925-280-0327 www.nelson-roseme.com VisualMesa Developer: Nelson & Roseme, Inc. Description: First principles model for complicated energy systems.

Master your semester with Scribd & The New York Times Special offer for students: Only $4.99/month. Ogontz Corporation

Plant Support Support & Evaluations, Inc. 282 Shellstone Court Naples, Florida 34119 888-615-3559 www.plantsupport.com

Steam Trap Database Software Developer: Plant Support and Evaluations, Inc Description: This free software was developed Microsoft Access and is an open environmen enable anyone to make changes to meet thei plant requirements.

Spirax Sarco Application Engineering Departm 1150 Northpoint Boulevard Blythewood, SC 29016 803-714-2000 www.spirax-sarco.com

SNAP3 Steam Needs Analysis Program Developer: Spirax Sarco Description: Total Steam System Software Prog for sizing and selecting: piping for steam/con densate/water, steam conditioning stations, pressure reducing stations, temperature cont stations, steam traps (all types and applicatio condensate recovery stations; flash steam reco systems, clean/pure steam systems.

STMS Steam Trap Management System Developer: Spirax Sarco Description: Windows-based software designe the easy collection, storage, organization, an sorting of steam trap data. It lets you create custom databases from survey sheets or a ha held Data Collector, then analyze by mainte  nance schedules, trap Read Free Forperformance, 30this Days Sign up totrap vote on title  application Useful or cost of steam loss, etc. Not useful

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Steam Conservation Systems

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Where to Thermon Corporation P.O. Box 609 San Marcus, TX 78667 800-820-4328 www.thermon.com SteamTrace 1.3 Developer: Thermon Corporation Description: Steam heat tracing design software. TLV Company TLV Company,, Ltd. 13901 South Lakes Drive Charlotte, NC 28273-67 28273-6790 90 704-597-9070 www.tlv.com TLV SE-1 STEAM Software Developer: TLV Company, Ltd. Description: Software to perform calculations for steam system components. Modules include Engineering Calculations, Steam Trap Selection, Pressure Reducing Valve Selection, Air Trap Selection, Gas Trap Selection, Air Vent Selection, Power Trap Selection, and Separator Selection.

UE Systems 14 Hayes Street Elmsford, NY 10523 800-223-1325 www.uesystems.com Ultraprobe 9000 Developer: UE Systems Description: Ultrasonic inspection and information storage system.

Master your semester with Scribd U.S. Army Construction Engineering Laboratory & The New York Times P.O. Box 9005 9005 Special offer forChamp students: OnlyIL $4.99/month. Champaign, aign, 61826 61826 800-USA-CERL

U.S. Department of Energy Industrial Technologies Program Room 5-F-065, MS EE-2F 1000 Independence Avenue, SW Washington, DC 20525 877-337-3463 www.eere.energy.gov/industry

3E Plus Insulation Appraisal software Developer: North American Insulation M turers Association Description: Calculates insulation thickn determine economic, energy, and envir savings for piping and equipment. Incl calculations for heat gain or heat loss, temperature requirements, condensatio heat loss efficiencies versus bare pipe, p periods, and emissions reductions.

Veritech Corporation 22960 Shaw Road, Suite 620 Sterling, VA 20166 703-435-78810 www.veritech-energy.com

ESteam Developer: Veritech Corporation Description: A steam system simulation developed in a Microsoft Excel environ model performs heat and mass balance allows flexibili flexibility ty for specifying condensa flash steam blowdown and deaeration letdown arrangements, and desuperhea configurations.

Washington State University  Read Free Foron 30this Days Sign up to vote title Cooperative Extension Energy Program  925 Plum Street, SE, Building 4 Not useful  Useful  Olympia,Cancel WA anytime. 98504-3165 800-373-2139

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Where to Find Help TrapMaster Developer: Yarway Corporation Windows-based s-based software designed for Description: Window the collection, storage, organization, and sorting of steam trap data. It lets you create custom databases from survey sheets or a handheld Data Collector,, then analyzes it in many different Collector ways. It is possible to create a historical record of an individual trap’s performance over many surveys. An extensive database of steam trap manufacturer’s models and performance data is built in for easy access.

Periodicals ASHRAE Journal American Society of Heating, Refrigeration, and Air Conditioning Engineers 1791 Tullie Circle, NE Atlanta, GA 30329 404-636-8400 www.ashrae.org Boiler Systems Engineering American Boiler Manufacturers Association 1300 East 9th Street Cleveland, OH 44114 216-696-7000 www.hpac.com/BSE/ Chemical Engineering Chemical Week Publishing 110 William Street New York, NY 10138 212-621-4900 www.che.com

Master your semester with Scribd & The New York Times Chemical Processing Putman Media Only $4.99/month. Special offer for students: 555 West Pierce Road, Suite 301

Atlanta, GA 30340 770-447-5083 www.aeecenter.com Energy User News Business News Publishing 1428-30 Midland Avenue #8 Bronxville, NY 10708 914-776-9241 www.energyusernews.com

Heating/Piping/Air Conditioning, HPAC, Engineerin Heating/Piping/Air Penton Publishing 1300 East 9th Street Cleveland, OH 44114 216-696-7000 www.penton.com Industrial Maintenance Maintenance & Plant Operation (IMPO) Reed Business Information 360 Park Avenue South New York, NY 10014 646-746-6400 www.cahners.com Mechanical Engineering, American Society Society of Mechanical Engineers (ASME) ASME International Three Park Avenue New York, NY 10016-5990 973-882-1167 www.asme.org Plant Engineering Reed Business Information 360 Park Avenue South New York, NY 10014 Read Free Foron 30this Days Sign up to vote title 646-746-6400  Useful  Not useful www.cahners.com Cancel anytime.

Plant Services

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Reports and Technical Papers American Gas Association (AGA) 400 North Capitol Street, NW Washington, DC 20001 202-824-7000 www.aga.org Energy Analysis Description: Contains information on boilers in leading manufacturing industries as it relates to natural gas. Solving Boiler Efficiency Problems Publication: Gas Technology: Natural Gas Applications in Industry, Summer 1996.

Armstrong International, Inc. 816 Maple Street Three Rivers, MI 49093 269-273-1415 www.armintl.com Capturing Energy Savings with Steam Traps Authors: Richard G. Bockwinkel and Scott A. French

GTI 1700 South Mount Prospect Road Des Plaines, IL 60018 847-768-0500 www.gastechnology.org Analysis of the Industrial Boiler Population Description: Report that identifies and characterizes the current industrial boiler population by fuel type and consumption, geographic location, industry, end user, and age. Publication, June 1993.

Master your semester with Scribd & The New York Times Special offer for students: Only $4.99/month. United Kingdom Energy Efficiency

U.S. Department of Energy Information P.O. Box 62 Oak Ridge, TN 37831 888-293-6498 www.osti.gov/bridge

Review of Orifice Plate Steam Traps Description: This report describes orifice mechanical steam traps. It also provides tion to help make decisions regarding ap for which orifice traps should be consi

U.S. Department of Energy Industrial Technologies Program Room 5-F-065, MS EE-2F 1000 Independence Avenue, SW Washington, DC 20525 877-337-3463 www.eere.energy.gov/industry

Overview of Energy Flow for Industries in S Industrial Classifications 20-39 Description: This report, sponsored by the mentt of Energy’s men Energy’s Industries of the Futu Practices activities, identifies and quanti energy supply and consumption in U.S. for heat and power by application.

Industrial Insulation for Systems Operating Ambient Temperature Description: This bulletin provides infor about the use of thermal insulation on p flat surfaces where their temperatures ar that of their surroundings (ORNL/M-46

Steam Digest Description: This annual compendium  of En published by the U.S. Department Read Free Foron 30this Days Sign up to vote title  the Alliance to Save Energy. It contains Useful Not useful   authoredCancel by a anytime. variety of manufacturers, laboratories, and solution vendors. It co technical and managerial aspects of ind

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Where to Find Help in both boiler operation and maintenance, and facility operations and maintenance.

American Boiler Manufacturers Association (ABMA) 4001 North 9th Street, Suite 226 Arlington, VA 22203-1900 703-522-7350 www.abma.com ABMA members offer an extensive listing of training courses in many aspects of boiler operations and maintenance. Visit www.abma.com/training.php for details.

American Society of Mechanical Engineers (ASME) Three Park Avenue New York, NY 10016-5990 800-843-2763 www.asme.org Area(s) covered: The ASME gives courses on repairs and alterations of boilers and pressure vessels.

Armstrong International, Inc. 816 Maple Street Three Rivers, MI 49093 269-273-1415 www.armintl.com Area(s) covered: Armstrong International has training facilities in which it sponsors Steam Energy Seminars and Education, and online steam training through Armstrong Steam University.

Master your semester with Scribd Association of Energy Engineers (AEE) 4025 Pleasantdale Road, Suite 420 & The New York Times Atlanta, GA 30340 Special offer for students: Only $4.99/month. 770-447-5083 www.aeecenter.org

courses in: • Boiler Condition Assessment and Monitori • Boiler Performance Analysis • Industrial Water-Tube Boiler • Oil/Gas-Fired Boilers

Boiler Efficiency Institute P.O. Box 2255 Auburn, AL 36831-2255 800-669-6948 www.boilerinstitute.com Area(s) covered: • Steam Plant Improvement • Workshop Engineering Fundamentals

CDT Micrographics 137 Water Street Exeter, NH 03833 603-778-6140 www.cdtmicrographics.com Area(s) covered: Hazards of Steam

Center for Professional Advancement (CFPA) P.O. Box 7077 44 West Ferris Street East Brunswick, NJ 08816-707 08816-7077 7 732-238-1600 www.cfpa.com Area(s) covered: The CFPA offers courses in: • Boiler and Steam System Management • Boiler Water Treatment • Piping Design, Analysis, and Fabrication • Pressure Vessel Design and Analysis  Read Free Foron 30 Days up to vote titleRetrofits & • Project Sign Management forthis Plant  Not useful Shutdowns  Useful  Cancel anytime. • Shell-and-Tube Heat Exchangers • Steam Turbines and Auxiliaries

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Wheree to Wher • Applications • Problem-solving and Troubleshooting • Plant Tour and Lab Demonstrations

Enercheck Systems, Enercheck Systems, Inc. P.O. Box 49426 Charlotte, NC 28277 704-841-9550 www.enerchecksystems.com Area(s) covered: • Performing a Steam Trap Survey • Performing a Compressed Air/Inert Gas Survey Sur vey • How to Make a Steam System Efficient

Industrial Interactions, Inc./BEI 8302 Professional Hill Drive Fairfax, VA 22031 703-573-4500 www.wetrainindustry.com Area(s) covered: Training courses in: • Boiler Operations and Maintenance • Industrial HVAC and Chillers • Facility Security and Emergency Guidelines • Water Chemistry in Boilers • Steam System Management Technical and consulting services include: Technical • Walk-through energy audits

Johnson Controls Institute 5757 North Green Bay Avenue Milwaukee Milw aukee,, WI 53201 53201 414-524-1200 www.johnsoncontrols.com

Master your semester with Scribd & The New York Times Special offer for Area(s) students: Only $4.99/month. covered: • Heat Pump Controls

New York State Energy Research and Development Authority (NYSERDA) 17 Columbia Circle Albany, NY 12203-6399 518-862-1090 www.nyserda.org

Area(s) covered: NYSERDA offers a varie opportunities for the commercial and sectors in New York State to become m efficient. For current opportunities, vis www.nyserda.org

North American Manufacturing Compan 4455 East 71st Street Cleveland, OH 44105 216-271-6000 www.namfg.com

Area(s) covered: • Combustion and Kiln Control • Effective Combustion and Its Contro • Optimizing Gas-Fired Industrial Heat Processes North Carolina State University Center for Boiler Studies Industrial Extension Services Campus Box 7902 Raleigh, NC 27695-790 27695-7902 2 919-515-5438 www.ies.ncsu.edu

Area(s) covered: • Energy Management Techniques • Customized On-Site Boiler Seminars • Measuring and Improving Boiler Effic  Read Free Forof 30Oil Days Sign up to vote on this titleNatural Gas • An Evaluation vs.  Useful  Not useful in Boilers Cancel anytime. • Improving Boiler Efficiency Through of Natural Gas

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Where to Find Help Plant Support Support & Evaluations, Inc. 282 Shellstone Court Naples, FL 34119 888-615-3559 www.plantsupport.com

Steam Economies Company 9325 Sutton Place Hamilton, OH 45011 513-874-8444 www.steameconomies.com

Area(s) covered: • Steam System Training to Four Different Levels • Customized On-Site Boiler Training • Customized On-Site Complete Steam System Training • Steam Trap Examiner Training (two levels) • Utility Optimization Training Training (steam and compressed air) • Steam Start-up and Shut-down Procedure Training • Defining and Resolving Waterhammer Training • On-site Steam System Assessments

Area(s) covered: • Boiler & Steam System Fundamentals • Understanding Your Steam Boiler System

Power Specialties Company Inc. & Power Specialties Service P.O. Box 9566 Raytown, MO 64133 816-353-1740 www.powerspecialties.com Area(s) covered: Power Specialties Company Inc. offers seminars to help optimize steam systems.

Spirax Sarco Application Engineering Department 1150 Northpoint Boulevard Blythewood, SC 29016 803-714-2000 www.spirax-sarco.com

Master your semester with Scribd Area(s) covered: Spirax Sarco offers an open universityNew programYork on cleanTimes steam utilization and a & The continuing education program on steam systems. Special offer for students: Only $4.99/month.

University of Tennessee Tennessee Energy, Energy, Environment and Resources Center 311 Conference Center Building Knoxville, TN 37996-413 37996-4134 4 865-974-4251 eerc.ra.utk.edu

Area(s) covered: • Boiler & Steam System Fundamentals • Energy Management Techniques • Customized On-Site Boiler and Steam Syste Seminars • Combined Heat and Power Fundamentals • Compressed Air Systems • On-site Assessments

University of Wisconsin-Madi Wisconsin-Madison/Extension son/Extension Departmentt of Engineering Professional Departmen Development 432 North Lake Street Madison, WI 53706 800-462-0876 epdweb.engr.wisc.edu

Area(s) covered: The University of Wisconsin a  Water Madison offers a course in Basic Boiler Read Free Foron 30this Days Sign up to vote title  Treatment.  Useful  Not useful Cancel anytime.

Yarway Corporation/Tyco Valve & Controls 9700 West Gulf Bank Road

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Armstrong International, Inc. 816 Maple Street Three Rivers, MI 49093 269-273-1415 www.armintl.com

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Guidelines for the Prevention of Water Hammer Description: Video identifies the most likely causes of water hammer and provides solutions that can be implemented to prevent it. (16 minutes) Guidelines for Steam System Efficiency Description: Video explaining basic consideration considerationss in the design, piping, and trapping of steam systems. (15 minutes)

Spirax Sarco Application Engineering D 1150 Northpoint Boulevard Blythewood, SC 29016 803-714-2000 www.spirax-sarco.com

Effective Condensate Drainage from Heat Description: This video highlights the op steam process equipment during change to address known problems of water ha and temperature fluctuations. (15 minu

Steam Boilers: The Inside Information Description: The video highlights intern response to on/off demand, high steam reduced boiler pressure, and change in dissolved solids (TDS). (12 1/2 minutes

Guidelines for Steam Trap Troubleshooting and Testing Description: Video outlining the need for establishing a preventive maintenance program and details what to look and listen for in testing steam traps. (18 minutes)

Let's Talk Steam Traps/Update Description: Video explaining the operating principles of the three types of steam traps: mechanical, thermostatic, and thermodynami thermodynamic. c. This tape helps users understand the internal operation of inverted bucket, F&T, thermostatic, and disc traps. (32 minutes) What Is Steam? Description: Video explaining the basics of steam. (15 minutes)

Master your semester with Scribd & The New York Times International District Energy Association Special offer for students: Only $4.99/month. 125 Turnpike Road, Suite 4 Westborough, MA 01581-2841


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Appendices The following appendices have been included in the Sourcebook:

Appendix A: Glossary of Terms This appendix contains a glossary of terms used in steam systems. N

N

Appendix B: Tip Sheets This appendix contains a series of steam system tip sheets. Developed by the U.S. Department of Energy Energy,, these tip sheets discuss common opportunities that industrial facilities can use to improve improve performa performance nce and reduce fuel use. Appendix C: Guidelines for Comment This appendix contains a form that provides a vehicle for submitting comments for improving the Sourcebook. N



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